JP2924145B2 - Pile fabric and method for producing the same - Google Patents

Description

Description: FIELD OF THE INVENTION The present invention relates to a pile fabric having a cut pile and a method for producing the same, which is excellent in printability, leveling property and feel on a pile surface, and has heat retention and bulkiness. An object of the present invention is to provide a pile fabric which has excellent properties and durability and is particularly suitable as a bedding.

(Prior Art) A pile fabric having a cut pile is formed by simultaneously knitting and weaving two upper and lower fabrics which are connected to each other using a double loom or a double Russell machine, and joining the upper and lower fabrics together. A method in which a yarn is cut in the middle of two cloths to form the binding yarn into a cut pile, and a method in which a loop pile fabric is manufactured using a normal loom or a knitting machine, and a tip of the loop pile is cut. Conventionally, a spun yarn made of a single fiber such as acrylic staple, rayon staple, wool, cotton, or the like has been used as a pile yarn. In addition, for the purpose of giving a soft texture to the cut pile, so-called thick and thin yarn made of synthetic fiber in which a thick part and a thin part are mixed in the fiber axis direction is used for the pile yarn, and heat treatment is performed after weaving. At this time, there is known a method in which a difference in heat shrinkage between a thin portion and a thick portion is used to generate a height difference in a pile height.

(Problems to be Solved by the Invention) However, the conventional cut pile fabric is excellent in terms of dyeing uniformity because the cut pile is composed of a single fiber. There were advantages and disadvantages in physical properties such as feel, texture, and pile durability.
For example, when a cotton yarn of a hydrophilic fiber is used for the pile yarn, it is excellent in heat retention, water absorption, feel, and the like, but is inferior in washing durability, pile shape stability, and the like. In addition, when acrylic fibers, which are most used for pile yarns in hydrophobic synthetic fibers, are used, dyeing properties, bulkiness, heat retention, feel, washing durability, etc. are excellent, but hygroscopicity, There is a problem in that the water absorption is poor, and the comfort of the bedding is lacking. Further, when thick and thin yarn is used for the pile yarn, there is a problem that moisture absorption and water absorption are poor as in the case of acrylic fiber.

The present invention provides a cut pile fabric which is excellent in heat retention, bulkiness and feel, has good moisture absorption and water absorption, and is excellent in pile washing durability and quick drying property.

(Means for Solving the Problems) The pile fabric according to the first invention has a cut pile composed of a blended yarn of hydrophilic fiber staples and hydrophobic fiber staples, and the above-mentioned difference in thermal shrinkage between the two fibers causes The length of the hydrophilic fibers constituting the cut pile is at least 1 mm longer than the length of the hydrophobic fibers, and the length of the hydrophilic fibers is at least 3 mm.

Further, the second invention relates to a method for producing the pile fabric of the first invention, wherein a hydrophilic fiber staple and a hydrophobic fiber staple having a boiling water shrinkage of 27 to 50% are mixed in a weight ratio of 50/50 to 80/20. Using the blended yarn obtained by blending as a pile yarn, a fabric having a cut pile having a pile height of 3 mm or more is manufactured, and the fabric is heat-treated to shrink the hydrophobic fibers in the cut pile, Characterized in that the height of the hydrophilic fiber is at least 1 mm lower than that of the hydrophilic fiber.

As the above hydrophilic fibers, the official moisture regain (JIS-L-1
[096] Examples include natural fibers such as cotton hemp, wool and silk, and regenerated chemical fibers such as viscose rayon and polynosic rayon. In addition, as the hydrophobic fiber, an acrylic fiber, a polyester fiber having an official moisture content of less than 5%,
Examples thereof include polyamide fibers and vinyl chloride fibers.

Also, to form a cut pile, as before,
Using a double loom, a double Russell machine or the like, the upper and lower two bonded fabrics are simultaneously knitted, and the binding yarn (pile yarn) connecting the upper and lower two fabrics is placed in the middle of the two fabrics. It is manufactured by a method of cutting into a cut pile, a method of manufacturing a fabric having a loop pile using a normal loom or a knitting machine, and cutting or shearing the tip of the loop pile. Further, the cut pile may be provided on only one surface of the other portion, or may be provided on both surfaces. The wet heat treatment can be performed also as a dyeing process.

(Function) After forming the cut pile, the fabric is treated with wet heat, so that the hydrophobic fibers in the fibers constituting the cut pile shrink and retract below the tips of the hydrophilic fibers, and the surface of the cut pile layer The portion is composed of one kind of hydrophilic fiber, and the part extending from the middle part to the deep part of the cut pile layer is composed of two kinds of fibers, hydrophilic fiber and hydrophobic fiber. Therefore, the surface layer of the cut pile has a leveling property, its feel is soft, the part from the middle part to the lower part is densely maintained, and the pile shape is maintained by the elasticity of the hydrophobic fiber.

However, if the length of the hydrophilic fibers constituting the cut pile of the pile fabric is less than 3 mm, the bulkiness is poor,
The feel as a pile fabric cannot be obtained. The length of the hydrophilic fiber is preferably at most 15 mm. When the boiling water shrinkage ratio of the hydrophobic fiber is less than 27%, the difference between the length of the hydrophilic fiber constituting the cut pile and the length of the hydrophobic fiber is reduced.
When the surface of the product becomes less than 1 mm, the effect of the hydrophobic fiber appears on the surface, and the printability, levelness and feel are reduced. On the contrary, when the boiling water shrinkage exceeds 50%, the hydrophilic fiber constituting the cut pile The difference between the length of the fiber and the length of the hydrophobic fiber exceeds 5 mm, and the hydrophobic fiber hardens and the brushing property deteriorates, and accordingly, the quality and hand of the product are reduced. Further, when the mixing ratio of the hydrophilic fiber and the hydrophobic fiber is less than 50/50, the amount of the water-impregnated fiber is too small, the hygroscopicity and the water absorption become insufficient, and the pile surface becomes sparse, and the lower hydrophobic When the fibrous fibers appear and the leveling property and hand are reduced, on the other hand, when it exceeds 80/20, the amount of the hydrophobic fibers becomes too small and the durability and the quick drying property of the pile become insufficient.

(Example) Tow of acrylic fiber of 3 denier (trade name "Exlan") was used as the hydrophobic fiber, the boiling water shrinkage was 0%,
Staples of 10%, 20%, 30%, 40%, 50% and 55% with a fiber length of 38 mm were prepared. Also, cotton fibers having an average fiber length of 28 mm were prepared as hydrophilic fibers. The above hydrophobic fibers and hydrophilic fibers are blended at a weight ratio of 50/50 to produce 7 types of blend yarns of English number 20/2, and these blended yarns are used as pile yarns and polyester is used as ground yarn. Using a multifilament yarn (150 denier, 30 filament) and an acrylic spun yarn (1/34 meter count), these yarns are converted to a double Russell machine (manufactured by KARL MAYER, 18 gauge, kettle spacing)
18mm, rotation speed 500r / m), knitting chain knitting with polyester multifilament yarn, and knitting with acrylic spun yarn, cut the pile yarn connecting the two ground structures in the middle, one side Fabric with a cut pile (pile length 9 mm, basis weight 600 g / m ² , course density 30 /
Inches). Next, printing was performed on the pile portion of the above-mentioned fabric with a reactive dye for cotton fibers, and saturated dye at 100 ° C.
Process for 2 minutes, and perform bulking and dye fixing at the same time,
Thereafter, the fabric was washed with water, softened, and dried to obtain a printed fabric. Then, the print fabric is passed twice through a brushing roller, and twice through a polisher in forward and reverse directions at 150 ° C.
Pass once at 0 ° C in the forward and reverse directions, and then at 100 ° C
After passing once in each of the forward and reverse directions, shearing of 2 mm was performed to trim the hair tips. After the finishing, the cut pile fabric had a pile length of 7 mm and a basis weight of 585 g / m ² . Vertical direction of this fabric 2m, width direction
It was cut to 1.4 m and a bias cloth was sewn around.

With respect to the seven types of pile fabrics obtained as described above, the bulkiness, the pile appearance after washing, and the print clarity were compared by the judgment of five panelists. The pile appearance after washing was measured using the household washing method (JIS-L-0217 105 washing and 601 drying three times) and commercial dry cleaning (adding 0.5% charge soap to petroleum solvent, washing time 10 minutes, draining 5 minutes, dry tumbler at 50 ℃
After 30 minutes (repeated three times), the quality was judged visually by the above-mentioned panelists. Table 1 shows the results. In addition, those judged as very good were marked with ◎, those judged as good with ○, those judged as slightly bad with 悪 い, those judged as bad with ×, and Xx indicate those determined to be bad.

As is clear from Table 1 above, Sample Nos. 4, 5, 6
Since the acrylic fiber (hydrophobic fiber) had an appropriate boiling water shrinkage, the bulkiness, the pile appearance after washing, and the print clarity were all excellent. On the other hand, sample numbers 1, 2,
No. 3, since the boiling water shrinkage rate of the hydrophobic fibers is low and shrinkage is insufficient, the pile tip side is formed only of hydrophilic fibers (cotton fibers), and the pile base side is formed of both hydrophobic fibers and hydrophilic fibers. The pile is not sufficiently layered, and the sharpness of the print decreases when shearing is performed in the final finishing process, and the pile is weakly fixed to the ground structure. The consequences were produced. Sample No. 7 in which the boiling water shrinkage exceeds 50%, the pile yarn is hardened by the wet heat treatment after knitting, the bulkiness is reduced, and the brushing resistance increases in the finishing step, and the cotton fiber Cotton loss increased.

Next, acrylic fiber (trade name "Exlan", fineness 2.2 denier, fiber length 38 mm, boiling water shrinkage 4
0%) and cotton fibers having an average fiber length of 28 mm as hydrophilic fibers, and the above two fibers are blended at various weight ratios to produce four kinds of blended yarns (English number 20/2). And a spun yarn consisting only of the above-mentioned cotton fiber, and commercialized in the same manner as the samples of Sample Nos. 1 to 7 above. The bulkiness, feel, pile appearance after washing, print clarity and officialness The moisture percentages were compared. The results are shown in Table 2 below.

As shown in Table 2, in Sample Nos. 9 to 11, bulkiness, feel, pile appearance after washing, clearness of print, and official moisture content (hygroscopicity) were obtained because the blend ratio of cotton fiber was appropriate. Of the sample No. 8 having a small amount of cotton fiber, the uniformity of the print was reduced, flickering occurred, the sharpness was lost, and the official moisture content, that is, the hygroscopicity was reduced, and On the other hand, in Sample No. 12, which consisted only of cotton fibers, the fixing force of the pile to the ground tissue was weakened, and the shape of the pile collapsed due to washing, resulting in poor appearance.

Next, a heat-shrinkable acrylic fiber (trade name: Xlan, fineness 2.2 denier, fiber length 38 mm, boiling water shrinkage 40%) as a hydrophobic fiber, and an average fiber length 28 as a hydrophilic fiber
mm cotton fibers were used, and both were blended at a ratio of 50/50 to produce a blended yarn having an English count of 20/2, which was referred to as pile yarn A. In addition, non-heat-shrinkable acrylic fiber (trade name: Xlan, fineness: 2 denier, fiber length: 80 to 100 mm) made by variably cutting the tow, and heat-shrinkable acrylic fiber made into staple by cutting the tow (Product name "Exlan", fineness 2 denier, average fiber length 90mm,
The acrylic worsted yarn having a metric count of 2/36 was manufactured by blending with a boiling water shrinkage ratio of 25%) at a weight ratio of 60/40. In addition, a cotton yarn having an English count of 20/2 was manufactured using a cotton fiber having an average fiber length of 28 mm.

The pile yarns A, B, and C are supplied to the same double Russell machine together with the ground yarns of the sample numbers 1 to 12, respectively, to knit a double knitted fabric having the same structure and the same course density. Cut pile yarn with one side, pile length 9mm
The pile fabrics A, B and C having the cut piles were obtained. The basis weight is 60 for pile fabric A using pile yarn A.
0 g / m ² , pile fabric B using pile yarn B was 570 g / m ² ,
The pile fabric C using the pile yarn C was 600 g / m ² .

Next, piles of pile fabrics A and C were printed with a reactive dye, and piles of pile fabric B were printed with a cationic dye, respectively, and treated with saturated steam at 100 ° C. for 20 minutes to perform bulky appearance and dye fixation. Subsequently, the pile fabrics A, B, and C were respectively passed through brushing rollers twice, and then a raising machine was raised on the back surface to form the same cut pile on the back surface and the front and back hair tips were sheared. Then, forward and reverse polisher processing is performed twice at a temperature of 150 ° C. on each of the front and back sides, and after brushing is performed, forward and reverse polisher processing is performed twice at a temperature of 120 ° C. on each of the front and back sides. Thereafter, the ends of the piles on the front and back sides were cut by 1 mm each by shearing to trim the length, and cut and sewn in the same manner as in Sample Nos. 1 to 12 to prepare double-sided blankets A, B, and C.

With respect to the double-sided blankets A, B and C, the bulkiness, the feel, the pile appearance after washing and the print clarity were compared in the same manner as described above, and the water transfer coefficient was further compared. However, the water transfer coefficient was determined as follows. That is, a heat source plate with a temperature of 37 ° C and a length and width of 25 cm is placed in a room of constant temperature and humidity, and a filter paper (moisture ratio 240
%, Water absorption 26 g) and a smooth knitted fabric made of a cotton yarn of No. 40 in the English style, are placed on top of each other, and a measurement sample (the double-sided blankets A, B, and C) is placed on the smooth knitted fabric. A temperature and humidity sensor is placed between the measurement sample and the smooth knitted fabric, and the temperature and humidity are measured at 30-second intervals until the equilibrium state is reached. The water vapor pressure (average value) was divided by the water vapor pressure (average value) on the measurement sample to obtain a water transfer coefficient. The results of the evaluation are shown in Table 3 below.

As apparent from Table 3 above, the double-sided blanket A of the present invention has a large heat shrinkage of the acrylic fiber even though the pile yarn is composed of the cotton fiber and the acrylic fiber having different dyeing properties. Therefore, clear prints were obtained in the same manner as the double-sided blankets B and C in which the pile yarn was made of one kind of fiber, and the change in the pile form due to washing was small, and the moisture transfer coefficient was large, so that comfortable sleep was obtained.

(Effects of the Invention) As described above, in the first invention, the cut pile is composed of a blended yarn of hydrophilic fiber and hydrophobic fiber, and the length of the hydrophilic fiber is reduced.
3 mm or more, and formed 1 mm or more longer than the hydrophobic fiber, so a clear print pattern can be obtained as if the pile was formed of a single fiber, and good bulkiness, feel and moisture absorption Thus, the pile form does not collapse after washing. According to the second invention, a blended yarn of a hydrophilic fiber and a heat-shrinkable hydrophobic fiber is used as a pile yarn, and the hydrophobic fiber is shrunk by wet heat treatment after weaving. Cut pile fabrics are easily obtained.

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁶ , DB name) D03D 27/00-27/10 D04B 21/02-21/04

Claims (2)

(57) [Claims] 1. A cut pile comprising a blended yarn of a hydrophilic fiber staple and a hydrophobic fiber staple, wherein the length of the hydrophilic fiber constituting the cut pile is hydrophobic due to a difference in heat shrinkage between the two kinds of fibers. A pile fabric formed so as to be 1 mm or more longer than the hydrophilic fiber, and the length of the hydrophilic fiber is 3 mm or more. 2. A hydrophilic fiber staple and a boiling water shrinkage ratio of 27.
Using a blended yarn obtained by blending 〜50% of hydrophobic fiber staples in a weight ratio of 50/50 to 80/20 as a pile yarn to produce a fabric having a cut pile having a pile height of 3 mm or more, This fabric is treated with moist heat to shrink the hydrophobic fibers in the cut pile, so that the height of the hydrophobic fibers is higher than that of the hydrophilic fibers.
A method for producing a pile fabric, wherein the pile fabric is lowered by 1 mm or more.