JPH04202836A - Highly stretchable pile fabric and its production - Google Patents

Abstract

PURPOSE:To obtain a pile fabric, having high stretchability and capable of exhibiting high-class and excellent finish according to uses by knitting pile yarn together with ground yarn composed of specific false twist textured multifilament yarn and then subjecting the resultant warp knitted pile fabric to heat treatment under relaxed conditions. CONSTITUTION:The objective pile fabric is obtained by knitting (B) pile yarn together with (A) false twist textured multifilament yarn of conjugate fiber in which a polymer part consisting essentially of polyethylene terephthalate and a polymer part consisting essentially of polytetramethylene terephthalate are compounded in a laminated state at >=60 number of crimps/25 mm of the respective filaments into a warp knitted pile fabric using a warp knitting machine having >=22 gage and then heat-treating the obtained knitted fabric under relaxed conditions. The aforementioned pile fabric is composed of a warp knitted fabric at >=55 yarns/25 mm course density and has >=20% elongation under 1kg/cm load in the warp and weft directions and >=95% recovery ratio after removing the above-mentioned load.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a highly elastic pile fabric and a method for producing the same.

[Prior Art] Conventionally, warp knitted pile fabrics have been widely used as upholstery materials for furniture chairs and surface covering materials for vehicle interior materials such as vehicle seats. In that case, the elasticity of the warp knitted pile fabric is utilized to fit and attach the pile fabric to the core of the chair or car side interior material. However, in recent years, as the trend toward luxury and individualization has progressed, the shapes of chairs and interior materials have become more complex.
Due to the diversification of materials, conventional warp knitted pile fabrics lack elasticity and do not fit well into cores for chairs and interior materials, resulting in sagging, making it difficult to obtain products with a good appearance. There is.

Furthermore, in sportswear and the like, there is an increasing demand for fabrics that fit the body well and follow the movements of the body, but pile fabrics that meet such requirements have not been known.

[Problems to be Solved by the Invention] The object of the present invention is to provide a material that has high elasticity, and even when used in products with complex and diversified shapes, can sufficiently fit the core body and exhibit a high-grade and good finish. To provide a pile fabric having satisfactory elasticity even when used for sportswear, etc.

[! Means for Solving a Problem] As a result of continued research, the present inventors found that the above object could be achieved by the following specific pile fabric.

That is, the present invention provides composite fibers (hereinafter referred to as r PET/PBT laminated conjugate fibers) in which a polymer part mainly composed of polyethylene terephthalate and a polymer part mainly composed of polytetramethylene terephthalate are composited in a bonded form. ”
It consists of a warp knitted fabric with a course density of 55/25 mm or more, which is made by knitting pile yarn into the ground texture of a multifilament false twisted yarn consisting of
The elongation rate under a Cm load is both 20% or more, and the elongation recovery rate in both the warp direction and the latitude direction after the same load is removed is 9.
This is a highly elastic pile fabric with a high elasticity of 5% or more.

Furthermore, the present invention also includes a method for manufacturing the above-mentioned highly elastic pile fabric, and the highly elastic pile fabric is made of PET/PBT in which the number of crimp of each filament is 60 pieces/25 ffim or more.
The ground yarn is made of multifilament false twisted yarn of laminated composite fibers, and the other yarn is pile yarn, and the final course density is equal to or greater than 55/25+nm on a warp knitting machine of 22 gain or more. This is a manufacturing method by knitting a warp-knitted pile fabric having a density lower than that, and then subjecting the warp-knitted pile fabric to a relaxation heat treatment.

The pile fabric of the present invention must have a course density of 55/25 squares or more. If the course density is lower than this, the dimensional stability of the fabric, the tension and elasticity of the fabric will be lost, the pile will fall out, become disordered, fall down, etc., and the stretch recovery rate of the fabric will also be low.

The upper limit of the course density is not particularly limited as long as the pile fabric can be knitted. However, the course density is 60/
Since it is often impossible to knit anything higher than 25 mm, it is desirable that the course density be in the range of 55 to 60/25 mm.

Furthermore, the pile fabric of the present invention has a longitudinal direction and a latitudinal direction.
Both elongation rates under a load of kg/cm must be 20% or more. If the elongation rate is lower than 20%, when the pile fabric is used as a covering material for chairs, etc., it will be difficult to stretch the fabric sufficiently along the shape of the core, and the workability of scratches will be poor, and it will be difficult to cover the core. I can't do it enough. In that case, it is necessary that the elongation rate in both the longitudinal and latitudinal directions is 20% or more, and even if the elongation rate in one direction (for example, the latitudinal direction) is 20% or more, the elongation rate in the other direction (for example, the longitudinal direction) is 20% or more. ) if the growth rate is lower than 20%, the intended purpose cannot be achieved. The upper limit of the elongation rate is not particularly limited, but if the elongation rate is too high, the elongation recovery rate tends to decrease, so the elongation rate is preferably in the range of 20 to 60% in both the longitudinal and latitudinal directions.

In that case, as long as the elongation rate is 20% or more, the elongation rates in the longitudinal and latitudinal directions may be the same or different,
For example, the elongation rate in the warp direction can be set to 30 to 40%, and the elongation rate in the weft direction can be set to 40 to 50%. This can be determined depending on the purpose of the pile fabric, the shape of the core to be covered, etc. I can do it.

Furthermore, the pile fabric of the present invention needs to have an elongation recovery rate of 95% or more in the longitudinal and latitudinal directions after removal of a 1 kg/cm load, and if the elongation recovery rate is lower than 95%, the elongation force When the fabric is released, it does not recover to its original size and does not fit properly to the core or body. Elongation recovery rate 100%
means a complete return to the original dimensions before applying the stretching force; from this point of view, it is desirable that the stretch recovery rate be close to 100%. In that case, it is necessary that both the elongation recovery rate in the longitudinal direction and the latitudinal direction be 95% or more, and even if the elongation recovery rate in one direction (e.g. the latitudinal direction) is 95% or more, the elongation recovery rate in the other direction (e.g. If the elongation recovery rate (in the warp direction) is lower than 95%, the intended purpose cannot be achieved. As long as the elongation recovery rate is 95% or more, the elongation rates in the warp direction and the weft direction may be the same or different. For example, the elongation recovery rate in the warp direction is 95% or more.
97%, and the elongation recovery rate in the weft direction can be 97 to 99%, which is preferably determined depending on the use of the pile fabric, the shape of the core to be covered, etc.

In manufacturing the above-mentioned pile fabric of the present invention, a base yarn consisting of multifilament false twisted processed yarn of PET/PBT laminated composite fibers in which the number of crimps of each filament is 60/25 cm or more is used. It is necessary to
In particular, it is preferable that the number of filament crimps is 60/25++m or more. When the number of crimps in each filament of the multifilament false twisted yarn is 60 pieces/25 m or more, the crimpability (K+ value) of each filament is 60% or more, and the crimp degree is 30% or more (Haton In all cases, the degree of residual crimp is 35% or more), the degree of residual crimp is 30% or more, and the degree of crimp elasticity is 90%, and the highly elastic pile fabric of the present invention can be produced. Therefore, in the present invention, the number of crimps in each filament of the multifilament false twisted yarn is 60/25 mm or more,
It is preferable that the K1 value is 60% or more, the crimp degree is 30% or more, and the residual crimp degree is 30% or more. In addition, the upper limit of the number of crimps of each filament is not particularly limited, but from the viewpoint of ease of handling the false twisted yarn and handleability of the knitted fabric, it is recommended that the number of crimps of each filament be 60 to 150/25 mm. is desirable.

The number of crimps of each filament of the multifilament false twisted yarn of PET/PBT laminated composite fiber used as the ground yarn is 60/25 mm or more, compared to the number of crimps of a general polyester false twisted yarn of about 20 to 25 mm. This is a very high value compared to the normal number of 10 to 30 crimps/25 mm, which naturally occurs due to the composite form of PET/PBT laminated composite fibers. can.

A PET/PB laminated composite filament with a number of crimps of 60/25s+m can be produced by spinning PET/PBT laminated composite fibers, sufficiently stretching the spun yarn using a conventional method, and then subjecting it to false twisting. .

Here, the course density, well density, elongation rate and elongation recovery rate in the warp and latitude directions of the pile fabric referred to in this specification, the number of crimp of the filament, the crimp property (Kl value), the crimp degree,
The degree of residual crimp and the crimp elastic modulus are measured as follows.

Course of pile fabric - Number of loops in the knitting direction of pile fabric (pieces/inch) Well of pile fabric - Number of loops in the width direction of pile fabric (pieces/inch) Pile
A grave with a length of 20e and a width of 1, with the mouth and meridian direction being the length direction.
Prepare a sample fabric of 0c size, hang it vertically and hold it over the entire width of 10 cm at the top, while applying a load of 10 kg uniformly over the entire middle 10 cm at the bottom (load: 1 kg). / cm), the length (Ll) (c) of the fabric after being left for 12 hours is measured, and the longitudinal elongation rate of the pile fabric is determined by the following formula.

Length 20cm, width 1 with the latitude direction being the length direction
Prepare a sample fabric of 0cm, hang it vertically and hold it over the entire width of the upper part]Ocm, and apply a load of 10kg uniformly to the lower part of the fabric over the entire width of 10cm (load 1 kg/cm), the length (Lz) (cm) of the fabric after being left for 12 hours is measured, and the longitudinal elongation rate of the pile fabric is determined by the following formula.

Length 20cm with the warp direction being the length direction.

Prepare a sample fabric with a width of 10 cm, hang it vertically and hold it over the entire width 10e of the upper part, while applying a load of 10 kg uniformly over the entire width of 10 cm on the lower part (load 1 kg/c■) for 72 hours, then the load was removed, and the length of the fabric (L s
)(cw+) and determine the longitudinal elongation recovery rate of the pile fabric using the following formula.

Length 20cm, medium 1, with the latitude direction being the length direction
Prepare a sample fabric of 0 cm, hang it vertically and hold it over the entire 10 cm width at the top, and apply a load of 10 kg evenly across the entire 10 cm width at the bottom (load 1 kg). / cm) for 72 hours, then the load was removed, and the length of the fabric (L4) (C■
) is measured and the latitudinal elongation recovery rate of the piled fabric is determined using the following formula.

It shows the number of crimps per fiber length of 25 cm under a load of 2B per denier.

After winding up the sample (filament) with a total winder until it reaches 5,000 denier (d), a 10g
Hang the load and fix this at the top center, 0.0 CI
A hot water treatment is carried out at 90° C. for 30 minutes under a load of I g/d. Next, after drying by leaving it at room temperature without any load, the yarn (filament) & after applying a load of 10 g again and leaving it for 5 minutes was measured.
■). Next, measure the thread (filament) length after applying a load of 1 kg and leaving it for 30 seconds, and calculate this as L b (a
Let m>. K.

The value is determined by the following formula.

Kl (%) -+ (L, -L,) /L, l X100
Take a filament of a certain length as a sample, and let the fiber (filament) length immediately after applying a load of 2 g per denier be A (am), and 50B per denier.
The length of the fiber (filament) immediately after applying the load is set as B (■), and is determined by the following formula.

A fixed length of filament is taken as a sample, and the fiber (filament) length immediately after applying a load of 2 g per denier is A (l), then 50 g per denier.
The fiber length after applying a load of 30 seconds and leaving it for 30 seconds is C (am)
shall be. Then, after removing the entire load and leaving it for 30 seconds, a load of 2 layers per denier was applied again, and the length of the fiber (filament) immediately after was determined as D (disgusting) by the following formula.

In the present invention, "polymer mainly composed of polyethylene terephthalate (PET) J and [polymer mainly composed of polytetramethylene terephthalate (PBT)
J refers to a polymer in which 80% by weight or more of the main chain is composed of ethylene terephthalate and tetramethylene terephthalate, respectively. PET and PBT are 20
Other copolymerized components (e.g., ethylene glycol, diethylene glycol, 1,4-butanediol, neopentyl glycol, cyclohexane-1,4-
dimethatol, isophthalic acid, sulfoyphthalic acid, polyalkylene glycol, etc.). PET and PBT may further contain fillers (carbon, silica, etc.), pigments, matting agents, antistatic properties improvers (for example, polyalkylene glycols having phenylene groups or benzenesulfonic acid groups, dodecylbenzenesulfonic acid, etc.) as necessary. ), flame retardants, dyeability improvers, and other additives.

In PET/PBT laminated composite fibers, it is best to select a low-viscosity PUT and a high-viscosity PBT to combine, especially when the intrinsic viscosity [η] is
A laminated conjugate fiber made by combining PET of 0.3 to 08 and PBT of 07 to 1.35 is desirable because it has a large number of crimps and high elasticity. On the other hand, laminated composite fibers made of high viscosity PET and low viscosity PBT are undesirable because their crimped form is reversed and their elasticity is insufficient.

In addition, a composite fiber consisting of a PE7 portion and a PBT portion, in which both are composited in a core-sheath type or multi-core type, cannot be obtained with a high number of crimp, and the high elasticity pile of the present invention cannot be obtained. Not suitable for making clay.

PE part in PET/PBT laminated composite fiber P
The ratio of the BT part is about 30:0 to about 70:30 by weight.
, especially i:40:60 to 60:40. P.E.
If the proportion of part 7 is less than 30% by weight, the crimped form of the filament becomes unstable, and the obtained fabric loses its stiffness and has a strong feeling of sagging. Also, the ratio of PBT part is 3
If the amount is less than 0% by weight, sufficient elasticity will not be obtained and the number of crimps will decrease.

The cross-sectional shape of the PET/PBT bonded composite fiber may be either circular or non-circular (irregular) (for example, oval, square, rectangle, rhombus, triangle, pentagon, star shape, etc.). Also,
As long as the PE7 portion and the PBT portion have a bonded structure, the specific content of the bonded structure may be of any kind.

The PET/PBT laminated composite fiber is manufactured by using a method in which the thickness of each filament (single filament denier) is approximately 2 to 8 d, and the number of filaments per multifilament is approximately 20 to 8 d.
Make sure that there are 50 pieces, and the temperature of the cap is about 265-290℃.
Approximately 800m/min to approx. 3000m/min from the porous cap.
Spinning at a spinning speed of minutes. After spinning, it is necessary to carry out sufficient stretching by a conventional method.

After spinning and drawing, the multifilament made of PET/PBT bonded composite fiber is subjected to false twisting. During this false twisting, normal false twisting conditions are used except that the heat setting temperature is 210°C or less. be able to. If the heat setting temperature is higher than 210° C., the occurrence of fuzz increases, which is not preferable. Note that as a false twisting method, a stretching and simultaneous false twisting method is also known, but when the stretching and simultaneous false twisting method is adopted, it is not possible to increase the number of crimps, so in the present invention, spinning, It is necessary to perform false twisting after stretching. In that case, drawing and false twisting may be directly connected and performed continuously, or after a drawn yarn is once produced by spinning and drawing, false twisting may be performed.

Furthermore, as the pile yarn, any of various synthetic fibers and yarns made of natural fibers used for furniture, clothing, industrial materials, etc. can be used, and the use, purpose, etc. of the pile fabric of the present invention can be used. It is best to select the appropriate one depending on the situation. The thickness of the pile yarn is not particularly limited, but is usually about 100 to 250.
d is good.

The warp knitted pile fabric of the present invention can be produced using a warp knitted pile fabric knitting machine such as a double raschel machine or a tricot machine. The pile in a terry cloth may be left in a loop shape or the tip may be cut to make it fluffy.

When knitting pile fabric, knit it so that it is equal to or slightly softer than the course density (55/25 mm or more) of the intended final product. The course density at the time of knitting is determined according to the shrinkage rate of the knitted pile fabric due to relaxation heat treatment. Generally, the course density is preferably about 0 to 20% lower, preferably about 8 to 15% lower than the course density of the final pile fabric subjected to relaxation heat treatment.

Next, the pile fabric produced by knitting is subjected to relaxation heat treatment.
Finish with a designed course density of 5/25++m or more. This relaxation heat treatment is usually carried out by soaking the knitted pile fabric at a temperature of about 120 to 135°C for about 90 to 120 minutes. At that time,
The relaxation heat treatment can also be carried out in a dyeing machine maintained under the above conditions, and in that case, the relaxation heat treatment and dyeing treatment of the pile fabric can be carried out at the same time.

[Effects of the Invention] The pile fabric of the present invention has high elasticity and extremely good elongation recovery, so when used as a surface material for furniture chairs, automobiles, railway vehicles, aircraft seats, etc. It fits well along the shape of the core and provides a beautiful finished surface.

Further, since the pile fabric of the present invention has high dimensional stability of the ground texture, it is easy to perform the lining work and a uniform lining can be obtained.

Moreover, since the pile fabric of the present invention has a high pile density, the pile layer has firmness, and the pile does not fall out, become disordered, or fall down, making it possible to provide a product with a high-class feel.

Furthermore, the pile fabric of the present invention can be used for various sports clothing such as ski wear and swimwear depending on the yarn used. Moreover, it is possible to provide a product that has good movement and comfort, and can follow the movements of the body well.

Next, the present invention will be specifically explained with reference to Examples, but the present invention is not limited thereto.

Example (A) PUT (proportion of ethylene terephthalate 100% by weight) with an intrinsic viscosity [η10.65] was melt-spun at a spinning temperature of 285° C. and a speed of 2000 m/min from a spinneret having 48 circular spinning holes, and Next, simultaneous stretching and false twisting was performed at a stretching ratio of 2.50 times, a false twisting speed of 300 m/min, and a temperature of 210°C to produce a drawn false twisted yarn (multifilament) of 150 d-48 filaments.

(B) PBT (proportion of tetramethylene terephthalate 100% by weight) with an intrinsic viscosity [η10.85] was spun from a spinneret with 48 circular spinning holes at a temperature of 265°C for 2000 min.
Melt spinning at a speed of 150d-48 filaments (multifilament) was carried out by melt spinning at a drawing ratio of 157 times, a false twisting speed of 300 m/min, and a temperature of 185°C. Manufactured.

(C) PET with an intrinsic viscosity [η] of 0.55 (50% by weight of ethylene terephthalate) and an intrinsic viscosity [η] of 0.9
7 PBT (proportion of tetramethylene terephthalate 50
weight%) from a spinneret with 48 circular spinning holes at a spinning temperature of 275°C and a speed of 2000 m/min to produce a laminated composite undrawn yarn (multifilament) (PET:
PBT weight ratio -1:1) was melt spun, then 2.
Stretching ratio of 20 times, false twisting speed 300 m/min, temperature 19
Drawing and simultaneous false twisting was performed at 0° C. to produce a drawn and false twisted yarn (multifilament) of 150d-48 filaments.

(D) The laminated composite undrawn yarn produced in the same manner as in (C) above was stretched at a stretching ratio of 2.10 times and a stretching speed of 800 m/min to produce a drawn yarn, and then false-twisted at a speed of 300 m/min. ,
False twisting was performed at a temperature of 195°C to produce a drawn false twisted yarn (multifilament) of 150d-48 filaments.

(E) Laminated composite undrawn yarn produced in the same manner as in (C) above at a stretching ratio of 2.10 times, a temperature of 195°C, and a false twisting rate of 1
Continuously stretched and false-twisted at 50m/min to 150d-4
An 8-filament drawn false twisted yarn (multifilament) was produced.

The processed yarn produced in (A) to (E) above is used as the ground yarn, and 20
Using 0d-48 filament raw silk as a pile yarn, a pile fabric having a density shown in the table below was knitted using a tricot machine (K S-3, manufactured by Nippon Meyer Co., Ltd.) with a gauge shown in the table below. Next, each pile fabric was immersed in Circular [Rapid type, bath ratio 1:15] for 90 minutes to perform a relaxation heat treatment to obtain a final pile fabric.

Each of the pile fabrics produced above was used to cover furniture chairs, and the finished state of the chairs was examined.

The above results are shown in the table below.

Type of processed yarn used ABCCDE (Control example) (Control example) (Control example) (Control example) (Example)
(Example) Number of residual crimps (%) 22.0
27.9 11,9 11,9 37,5 3
7.1 Wool density (/25 degrees) 28 28 2
8 34 28 28 wool density (/25
m+) 30 30 30 35
30 30 latitude (%) 85-8888-928
6~9085~8897~9998~99 falls
Yes Yes Yes Yes Yes No None From the results in the table above, the pile fabric of the present invention has a high elongation rate and elongation recovery rate, is rich in elasticity, does not cause the pile to fall out, become disordered, fall down, etc., and can be used for chairs, etc. It can be seen that when used as a coating material, it fits well on the core and gives a fine, wrinkle-free and beautiful finish.

Claims (1)

[Scope of Claims] 1) A multifilament false twisted yarn consisting of a composite fiber in which a polymer part mainly composed of polyethylene terephthalate and a polymer part mainly composed of polytetramethylene terephthalate are laminated together. Consisting of a warp knitted fabric with a course density of 55/25 mm or more with pile yarn knitted into the ground weave, and an elongation rate of 20% or more under a load of 1 kg/cm in both the warp and weft directions, and after the same load is removed. A highly elastic pile fabric characterized by having an elongation recovery rate of 95% or more in both the longitudinal and latitudinal directions. 2) Composite fiber in which a polymer part mainly composed of polyethylene terephthalate and a polymer part mainly composed of polytetramethylene terephthalate are combined in a laminated form, in which the number of crimps in each filament is 60 pieces/25 mm or more. A warp knit pile fabric having a density equal to or lower than the final course density is knitted using a warp knitting machine of 22 gauge or higher using a ground yarn consisting of a multifilament false twisted yarn, and then The warp-knitted pile fabric is made of a warp-knitted fabric with a course density of 55/25 mm or more, characterized by subjecting the warp-knitted pile fabric to relaxation heat treatment, and has an elongation rate of 20% or more under a load of 1 kg/cm in both the warp and weft directions. A method for producing a highly elastic pile fabric, characterized in that the elongation recovery rate in both the warp direction and the weft direction after the same load is removed is 95% or more.