JP2008169517A - Pile fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pile fabric so designed that pile fiber-melted film 14 constituting recesses forming an uneven pattern of the pile surface of the fabric is made to be free from crack, peeling and coming-off. <P>SOLUTION: The pile fabric is such as to be designed in the following way: Piles 13 are constituted of high-melting fibers 11 and low-melting fibers 12 differing in melting point from each other, and being 5 dtex or less in single fiber fineness (M) and the thickness (H) of the pile layer is 2.0 mm or less. The pile density (N) represented as the number of piles per unit area of 25.4 mm<SP>2</SP>is 1,000/(25.4 mm)<SP>2</SP>or higher, and the pile fiber density (R) per unit area of 25.4 mm<SP>2</SP>, represented as the product (Q×N) of the number of fibers constituting the piles and the pile density (N), is 300,000/(25.4 mm)<SP>2</SP>. The ratio of the blend mass of the low-melting fibers 12 to the total mass of the piles is 10-70%, and the blend number ratio of the low-melting fibers 12 to the total pile fibers constituting the piles 13 is 7-50%. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a pile fabric suitable for a surface material covering a surface of a chair stretch fabric, that is, a backrest of a chair or a seat surface.

  It is known to draw a concavo-convex pattern by partially heating and pressing a pile surface (see, for example, Patent Document 1). The pile surface is composed of piles planted on the base fabric, and since the piles are rich in cushioning properties, the piles of the recesses set by heating and pressing are gradually brought back to their original upright state by their elastic restoring force. It is easy to restore and the uneven pattern drawn on the pile surface is likely to disappear.

  Therefore, a method is adopted in which the pile fiber is heated and melted at the time of heating and pressing, and the valley bottom of the concave portion is set by the molten film. However, since the pile layer is rich in cushioning properties and heat insulation properties, it is difficult for heat at the time of heating and pressing to reach the root of the pile. Therefore, the pile fiber melt film formed on the valley bottom of the concave part is hidden under the film and floats on the pile fiber of the root part of the pile that has not melted, and the pile fiber elasticity of the root part The molten film on the valley bottom of the concave portion is easily pushed up by the restoring force, and at that time, a crack is generated and the molten film on the valley bottom is easily peeled off.

  Therefore, in a pile fabric in which high melting point fibers and low melting point fibers are mixed in a pile, heating and pressing are repeated a plurality of times (for example, see Patent Document 2).

Japanese Patent Laid-Open No. 56-107065 (Japanese Patent Publication No. 62-15667) JP 59-094671 (JP-B 62-57735)

Since the pile layer is rich in cushioning properties and heat insulation properties, if it is heated and pressed deeply so that the molten film on the valley bottom of the recess is fused to the base fabric, the base fabric is easily torn at the valley bottom of the recess.
Therefore, when a deep recess is formed in the pile fabric by heating and pressing as described above, it is necessary to bond a reinforcing lining to the back surface of the pile fabric.
The method of forming the deep recess is limited to a carpet pile fabric using a thick and strong base fabric (see, for example, Patent Document 2), and the vehicle seat pile fabric, particularly the base fabric is thin. It is difficult to apply to the pile fabric.

  Accordingly, the present invention provides a vehicle seat for use in which the molten film on the valley bottom of the concave and convex portion of the concave and convex pattern drawn by heating and pressing on the pile surface is made to adhere to the base fabric and is difficult to peel and fall off, and the pile surface is constantly rubbed. It aims at obtaining the pile fabric suitable for a surface material.

In the pile fabric according to the present invention, (a) a concave / convex pattern is depicted on the pile surface 15 by a concave portion 17 having a valley bottom formed by a melt film 14 of heated and pressed pile fibers, and (b) the tip of the pile 13 The pile layer from the base fabric 18 to the base fabric 18 has a thickness (H) of 2.0 mm or less, (c) a single fiber fineness (M) of 5 dtex or less, and a high melting point fiber 11 and a low melting point fiber 12 having different melting points. And (d) the base fabric 18 that locks the pile 13 is composed of high-melting fibers having a melting point higher than that of the low-melting fibers 12 constituting the pile 13, e) The pile density (N) indicated by the number of piles per unit area 25.4 mm square is 1000 pieces / (25.4 mm) ² or more, and (f) the number of fibers constituting the pile yarn (Q ) And pa Le density (N) and the product (Q × N) per unit area is shown as a 25.4mm square per pile fiber density (R) is 300,000 or present /(25.4mm) ² or more, the (g) the pile 13 The mixed fiber mass ratio of the low melting point fiber 12 in the total mass is 10 to 70%, and (h) the mixed fiber number ratio of the low melting point fiber 12 in the total number of pile fibers constituting the pile 13 is 7 to The first characteristic is 50%.

  The second feature of the pile fabric according to the present invention is that, in addition to the first feature, the high-melting fiber 11 constituting the pile 13 is a polyethylene terephthalate fiber, and the low-melting fiber constituting the pile 13 12 is a polytrimethylene terephthalate fiber, a polypropylene terephthalate fiber or a polybutylene terephthalate fiber.

In the present invention, the pile 13 is composed of the high-melting fiber 11 and the low-melting fiber 12 because the high-melting fiber 11 is difficult to melt and is in the melt film 14 formed by the low-melting fiber 12 and serves as a reinforcing material. The melt film 14 is difficult to crack, and even if the melt film 14 is in close contact with the base fabric 18, the melt film 14 is not fused and lacks elasticity compared to the base fabric 18. In order to avoid bending and becoming separated from the base fabric 18, the mixed fiber mass ratio of the low melting point fibers 12 in the pile yarn is set to 10 to 70%.
That is, if the mixed fiber mass ratio of the low-melting fiber 12 is 70%, almost all pile fibers at the heat-pressed portion are melted, the melt film 14 is fused, and the base fabric 18 is hard and easily cracked. On the contrary, if the mixed fiber ratio of the low melting point fiber 12 is less than 10%, the molten film 14 is lifted from the base fabric 18, and the high melting point fiber 11 is melted by the melt of the low melting point fiber 12. Between the high melting point fiber 11 and the high melting point fiber 11, and the melt film 14 is easily cracked between the high melting point fiber 11 and the high melting point fiber 11. Is preferably 20% or more.

In the present invention, the low-melting fiber 12 has a mixed fiber mass ratio of 70% or less because, for example, the low-melting fiber 12 such as polytrimethylene terephthalate fiber, polypropylene terephthalate fiber, polybutylene terephthalate fiber, etc. On the other hand, the physical strength is inferior to that of polyethylene terephthalate fiber, which is the high melting point fiber 11, and when the mixed fiber mass ratio of the low melting point fiber 12 is 70% or more, the pile is easily pushed down and the pile surface is easily worn. In addition, it is difficult to obtain a durable pile fabric that is wear-resistant and suitable for a chair upholstery.
Further, since the burning rate in the flammability test according to the American automobile safety standard FMVSS 302 is increased according to the mixed fiber mass ratio of the low melting point fiber 12, the mixed fiber mass ratio of the low melting point fiber 12 is also related to the automobile safety standard. Is 70% or less, preferably 50% or less.

In the present invention, the single fiber fineness (M) of the high-melting fiber 11 and the low-melting fiber 12 is set to 5 dtex or less, and the mixed fiber number ratio of the low-melting fiber 12 to the total number of pile fibers constituting the pile 13 is 7 Even if the mixed fiber mass ratio of the low melting point fiber 12 is 70%, if the single fiber fineness is thick, the high melting point fiber 11 and the low melting point fiber 12 are not evenly mixed, This is because the melt film 14 formed by the low melting point fiber 12 is divided by the high melting point fiber 11 and is not continuous, and the melt film 14 is easily cracked.
Therefore, in the present invention, in order to ensure that the high melting point fibers 11 and the low melting point fibers 12 are mixed evenly, the blend ratio of the low melting point fibers 12 is set to 7% or more, preferably 15% or more. .
In that case, when the mixed fiber number ratio of the low melting point fiber 12 exceeds 50% and the mixed fiber number ratio of the high melting point fiber 11 is less than 50%, the high melting point fiber 11 is formed on the melt film 14 formed by the low melting point fiber 12. The reinforcing effect of the high-melting fiber 11 that serves as a reinforcing material in the molten film 14 is not evenly mixed, and the reinforcing effect of the high-melting fiber 11 is lowered. Flexibility is suppressed, and the texture of the pile fabric is easily damaged.

In the present invention, the pile density (N) is 1000 pieces / (25.4 mm) ² or more, and the pile fiber density (R) is 300000 pieces / (25.4 mm) ² or more. This is so that a continuous melt film 14 is formed without being divided for each pile or pile fiber, and by doing so, the melt film 14 is bonded to the base fabric 18 via the countless high melting point fibers 11. In addition, the peeling stress does not concentrate on the molten film 14 via some of the high melting point fibers 11, and as a result, the molten film 14 is difficult to crack and is difficult to peel.

In the present invention, the thickness (H) of the pile layer extending from the tip of the pile 13 to the base fabric and the root is set to 2.0 mm or less without the molten film 14 generated by heating and pressing being obstructed by the thick pile layer. This is for forming a thin, flexible, and hard-to-crack film that is lightly adhered to the base fabric 18 to the extent that it is slightly touched by being blocked by the high-melting fiber 11, and preferably has a pile layer thickness (H) of 1. 5 mm or less.
As such, even if the melt film 14 is thin, the mixed high-melting fiber 11 and low-melting fiber 12 are uniformly mixed to form a tough film such as a thin, smooth film without fine irregularities.

  Thus, according to the present invention, the concave / convex pattern is drawn on the pile surface 15 by the concave portion 17 in which the valley bottom is formed by the melt coating 14 of the pile fiber that is heated and pressed, and the melt coating 14 is thin, tough and hardly cracked. A pile fabric suitable for a chair upholstery of an automobile seat that is used without being easily peeled off and being rubbed against the pile surface continuously is obtained.

For the low melting point fiber 12, a core / sheath composite fiber having a low melting point polymer as a sheath component and a high melting point polymer as a core component can be used.
In order to form a melt film 14 having a uniform thickness that is thin, flexible, and difficult to crack by heating and pressing the pile surface 15, it is shown as the product of the pile fiber density (R) and the single fiber fineness (M) of the pile fiber. A pile / decitex equivalent density (S) of the pile layer is preferably set to 300000 dtex / (25.4 mm) ² or more.

In general, the bulk specific gravity of a pile layer is calculated by the mass of the pile fiber cut from the unit area of the pile fabric and the thickness of the pile layer.
However, in the present invention, it is extremely difficult to cut the pile fiber with a pile fabric having a pile layer thickness t of 2.0 mm or less. Therefore, the pile density (N) and the number of fibers constituting the pile yarn (Q ) And the pile fiber single fiber fineness (M), the pile / decitex equivalent density (S) is substituted for the bulk density of the pile layer.
The “pile / decitex equivalent density (S)” as used herein refers to a single fiber when all the pile fibers included in the unit area (25.4 mm) ² of the pile fabric are combined into a single thick fiber. , That is, the fineness of one virtual thick pile fiber planted within the unit area (25.4 mm) ² of the pile fabric.
In the present invention, when the pile / decitex equivalent density (S) of the pile layer is 300000 dtex / (25.4 mm) ² or more, preferably 500000 dtex / (25.4 mm) ² or more, the molten film 14 is heated and pressed. It is pushed back to the root 19 of the pile that remains slightly without being melted, or it does not break when it hits the root 19, especially when the number of pile fibers intervening in the unit area (25.4 mm) ² is 300000 or more. If present, the mixed high-melting-point fibers 11 and low-melting-point fibers 12 are uniformly mixed to form a tough film such as a thin, smooth, fine film having no unevenness.

The heating pressing of the pile surface 15 is performed according to a conventional method using a heating embossing roll.
At the time of heating and pressing the pile surface, the base fabric 18 is made of fibers having a higher melting point than the low melting point fibers 12 of the pile 13, and therefore is not torn or deformed.
The boundary between the pile surface 15 and the concave portion 17 becomes the groove wall 16 by the pile fibers 11 and 12 heated and melted. The width (W) of the valley bottom 14 is the distance (V) from the pile surface 15 to the valley bottom 14. Make it more than 3 times.
As described above, the width (W) of the valley bottom 14 is set to be three times or more the distance (V) from the pile surface 15 to the valley bottom 14 by receiving the radiant heat from the heating pressing mold at the time of heating and pressing. The pile fiber at the periphery also melts, but in the pile layer having a thickness (H) of 2.0 mm or less, there is little melting at the periphery of the valley bottom 14, which melts and the inclined groove wall 16 having a width of 1 to 2 mm forms the valley bottom. 14 so that the valley bottom 14 is edged, and the difference in appearance between the fuzzy pile surface 15 and the film-like valley bottom 14 does not disappear. Even if the depth is around 1 mm, a three-dimensional concavo-convex pattern is drawn.
Even if the pile fabric used for the chair upholstery is pushed down and the pile layer is thinned in the use, the uneven pattern due to the difference in appearance between the fuzzy pile surface 15 and the film-like valley bottom 14 In the pile layer originally having a thickness (H) of 2.0 mm or less, the impression that the exceptional pile 13 is pushed down is not given.

Polyethylene terephthalate multifilament yarn having a single fiber fineness of 1.17 dtex / total fineness of 84 dtex as the high melting point fiber 11, polyethylene terephthalate / multifilament yarn having a single fiber fineness of 1.17 dtex / total fineness of 168 dtex, a single fiber fineness of 1.17 dtex / total fineness A 252 dtex polyethylene terephthalate multifilament yarn, a single fiber fineness 1.17 dtex / total fineness 336 dtex polyethylene terephthalate / multifilament yarn, and a single fiber fineness 1.17 dtex / total fineness 420 dtex polyethylene terephthalate / multifilament yarn were prepared.
The low melting point fiber 12 is a polybutylene terephthalate multifilament yarn having a single fiber fineness of 1.17 dtex / total fineness of 168 dtex, a single fiber fineness of 3.50 dtex / polybutylene terephthalate / multifilament yarn having a total fineness of 84 dtex, a single fiber fineness of 3.50 dtex / Polybutylene terephthalate / multifilament yarn having a total fineness of 168 dtex, single fiber fineness of 3.50 dtex / polybutylene terephthalate / multifilament yarn having a total fineness of 252 dtex, single fiber fineness of 3.50 dtex / polybutylene terephthalate / multifilament yarn having a total fineness of 420 dtex, A polybutylene terephthalate multifilament yarn having a single fiber fineness of 3.50 dtex and a total fineness of 336 dtex was prepared.
A pile yarn was prepared by blending the high melting point fibers (polyethylene terephthalate / multifilament yarn) 11 and the low melting point fibers (polybutylene terephthalate / multifilament yarn) 12, and the warp density was 36 / 25.4 mm, the weft density. A 52 / 25.4 mm moquette (pile fabric) was woven, and an uneven pattern was drawn on the pile surface using a heated embossing roll, and texture, crack resistance, film peeling resistance and flammability were evaluated.
The specifications and evaluation of the pile fabric are as shown in Tables 1 and 2.

[Evaluation methods]
As for the texture of the pile fabric, each of the three inspectors (panels) compares the pile fabrics of Examples 1 to 6 and Comparative Examples 1 to 8 with a pair of comparisons. For the pile fabrics recognized as “poor texture”, the evaluation score was 0 points, and an average score of 0.75 points or more for each evaluation score was “◎” and the average score was 0.55- Pile fabric with 0.74 points is indicated with “○”, pile fabric with average points of 0.35 to 0.54 is indicated with “△”, and pile fabrics with average points of 0.34 or less are indicated with “×”. To do.

  Regarding the occurrence of crack resistance of the pile fabric, the pile fabrics of Examples 1 to 6 and Comparative Examples 1 to 8 were tested by the JIS-L-1096 (8.17.2) B method, and the molten film 14 of the hot pressing recess 17 was observed. In addition, a pile fabric with no or almost no cracks is marked with “◎”, and cracks are slightly recognized, but a pile fabric that is almost inconspicuous is marked with “○”, but cracks are clearly recognized, but No pile fabric is indicated by “Δ”, cracks are clearly recognized, and conspicuous pile fabric is indicated by “x”.

  For peeling resistance of pile fabric, a metal friction element (mass 200 g) was used in the friction tester type 2 (Gakushin type) of JIS-L-0 849 (5.1-b), and the tip contact surface was vertical. 2 mm, width 4 mm, test piece size 30 mm wide, length 250 mm, load 4.9 N, reciprocating distance 100 mm, reciprocating speed 30 times / min. In addition, a pile fabric with no or almost no film peeling is observed with “◎”, and a slight film peeling is recognized, but an almost inconspicuous pile fabric with “○” is clearly recognized. However, an inconspicuous pile fabric is indicated by “Δ”, peeling of the film is clearly recognized, and an outstanding pile fabric is indicated by “x”.

  About the flammability of a pile fabric, it performed by the US automobile safety standard FMVSS302 horizontal method according to JIS-D-1201, and the flame which contacted one end of the sample supported horizontally is a mark line between mark lines (254mm * 10cm). Evaluated by the burning rate moving between.

1 is a cross-sectional perspective view of a pile fabric according to the present invention.

Explanation of symbols

11: High melting point fiber 12: Low melting point fiber 13: Pile 14: Film (valley)
15: Pile surface 16: Groove wall 17: Recess 18: Base fabric 19: Root

Claims (2)

(A) A concave / convex pattern is depicted on the pile surface (15) by the concave portion (17) in which the valley bottom is constituted by the melt film (14) of the heated pile fiber,
(B) The thickness (H) of the pile layer extending from the tip of the pile (13) to the base fabric (18) is 2.0 mm or less,
(C) The pile (13) is composed of the high melting point fiber (11) and the low melting point fiber (12) having a single fiber fineness (M) of 5 dtex or less and different melting points,
(D) The base fabric (18) for locking the pile (13) is composed of high melting point fibers having a higher melting point than the low melting point fibers (12) constituting the pile (13),
(E) The pile density (N) indicated by the number of piles per unit area of 25.4 mm square is 1000 pieces / (25.4 mm) ² or more,
(F) 300,000 pile fiber density (R) per unit area 25.4 mm square shown as the product (Q × N) of the number (Q) of fibers constituting the pile yarn and the pile density (N) /(25.4 mm) ² or more,
(G) The mixed fiber mass ratio of the low melting point fiber (12) in the total mass of the pile (13) is 10 to 70%,
(H) A pile fabric in which the ratio of the number of mixed fibers of the low melting point fibers (12) in the total number of pile fibers constituting the pile (13) is 7 to 50%.   The high melting point fiber (11) constituting the pile (13) is polyethylene terephthalate fiber, and the low melting point fiber (12) constituting the pile (13) is polytrimethylene terephthalate fiber, polypropylene terephthalate fiber or polybutylene. The pile fabric according to claim 1, which is a terephthalate fiber.

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