JPH08302564A - Production of stretchable fabric - Google Patents

Abstract

PURPOSE: To enable the production of a fabric having excellent stretchability and produce a stretchable fabric capable of reducing a change in product density based on the weaving density, facilitating the regulation of the product density and further the touch feeling or appearance, shape, etc., of the product and producing the appropriate product according to demands. CONSTITUTION: This method for producing a stretchable fabric comprises a step for preparing a special textured yarn 10 containing a covering yarn 12 intertwisted around the outer periphery of a core yarn 11 comprising dissolvable and decomposable type fibers, a step for weaving the special textured yarn 10 as at least either of warp and weft yarns and affording a woven fabric intermediate product and a step for dissolving or decomposing the dissolvable and decomposable type fibers in the woven fabric intermediate product and providing the fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a stretchable fabric which can be suitably used for manufacturing a skin material such as a seat, a door trim and a console box in an automobile, and particularly for manufacturing a skin material such as a moquette.

[0002]

2. Description of the Related Art Conventionally, a moquette used as a skin material for an automobile seat or the like is composed of a cloth having a pile layer on its front surface and a backing layer on its back surface.

Examples of the ground yarn which constitutes the ground structure of such a moquette include, for example, polyester / rayon blended yarn,
Polyester fiber spun yarn or polyester fiber processed yarn is used. However, since the moquette of this configuration has an elongation at break of about 20% and poor elasticity,
Even if it is molded or sewn for a skin material such as a vehicle seat, it does not fit to the vehicle seat and wrinkles are generated, so that it is difficult to obtain a good finish.

On the other hand, in the past, as a moquette having high elasticity, there has been one in which a processed yarn obtained by double-covering the above-mentioned ground structure yarn is used as a spandex yarn. That is, the processed yarn is woven as a base yarn to form a pile fabric, the fabric is heated to shrink the fabric together with the spandex, and then a backing material is applied to the back surface of the fabric.

In this moquette, in addition to the amount of expansion and contraction of the ground yarn itself, the contraction of the cloth also extends, so that a high expansion and contraction rate can be obtained.

However, in this moquette manufacturing method,
Since the woven fabric is shrunk, the product density changes with respect to the weaving density, and it is difficult to adjust the texture and appearance of the product (moquette). Moreover, in this manufacturing method,
If there is no gap between the warp yarns or the weft yarns in the ground structure, it cannot be further shrunk, and there has been a problem that the shrinkage amount, that is, the stretch amount cannot be secured sufficiently large.

The present invention solves the above-mentioned problems of the prior art, can produce a fabric having excellent stretchability, and can reduce the change in product density with respect to the weaving density, thereby adjusting the product density and thus the texture of the product. It is an object of the present invention to provide a method for manufacturing a stretchable fabric, which allows easy adjustment of the outer shape and the like, and can manufacture an appropriate product according to demand.

[0008]

In order to achieve the above object, the present invention provides a step of preparing a specially processed yarn in which a flower yarn is twisted around an outer periphery of a core yarn made of a meltable / degradable fiber, The method includes the steps of weaving the processed yarn into at least one of the warp yarn and the weft yarn to obtain a woven intermediate product, and dissolving or decomposing the dissolved / degradable fibers in the woven intermediate product to obtain a fabric. The gist is a method of manufacturing a stretchable fabric.

In the present invention, it is preferable that the specially processed yarn is formed by twisting a holding yarn made of a soluble / degradable fiber around the flower yarn.

In the present invention, it is more preferable to use water-soluble vinylon or rayon fiber as the soluble / degradable fiber.

In the present invention, it is even more preferable that the filament is made of polyester fiber.

In the present invention, as the specially processed yarn,
It is preferable to use the yarn in which the yarn is over-fed with the core yarn at a feed rate of 110 to 150% and twisted with the core yarn.

In the present invention, it is preferable that a pile layer is provided on one surface of the cloth and a backing layer is formed on the other surface of the cloth.

In the present invention, the backing layer is
It is even more desirable to use an acrylic, urethane, ethylene / vinyl acetate copolymer (EVA), vinylidene chloride, or styrene / butadiene rubber (SBR) stretchable resin.

In the present invention, the term "dissolvable / decomposable fiber" refers to a fiber which is decomposed to such an extent that the elongation of filaments can not be restricted due to factors such as heat, light, radiation, oxygen and water, or Fiber that dissolves in a specific solvent to the extent that the elongation of filaments can not be restricted or even more.

The detailed construction of the present invention will be described below by taking as an example the case of producing a moquette for a skin of a vehicle seat according to the present invention.

As shown in FIG. 1, this moquette is made of a warp pile fabric, and one face of the ground structure (1) made of the warp yarn (1a) and the weft yarn (1b) is formed from the pile yarn (2). And a backing layer (3) is formed on the other surface.

In the present invention, the specially textured yarn (10) is used as at least one of the warp yarn (1a) and the weft yarn (1b) constituting the ground structure (1) of the moquette.

As shown in FIG. 2, in the specially processed yarn (10), the yarn (12) is twisted around the outer periphery of the core yarn (11), and the yarn (12) is pressed down from the outer periphery. 13) is twisted together.

Core yarn (11) in specially processed yarn (10)
Is composed of a spun yarn of meltable / degradable fiber.
In the present invention, as the soluble / degradable fiber, any fiber can be used as long as it is a fiber specified by the above definition. For example, water-soluble vinylon, rayon fiber and polynosic fiber which are soluble in a specific solvent, etc. Among them, the core yarn (11) made of water-soluble vinylon is preferably used since the dissolution treatment in the subsequent step can be easily performed, and particularly, the dissolution temperature in a water bath is 20 to 140 ° C, more preferably the lower limit is 23 ° C
As described above, it is preferable to use one having an upper limit value of 80 ° C. or less.

From the viewpoint of weaving processability, the core yarn (11) preferably has a tensile strength of 50 gf or more, preferably 100 gf or more, and further improves meltability / decomposability in post-processing. Thickness is 10 to 150D
(Denier), preferably having a lower limit value of 20D or more and an upper limit value of 80D or less.

The core yarn (11) may be a single yarn, a compound yarn or a twisted yarn.

The flower yarn (12) to be twisted around the core yarn may be any one as long as it is generally used as a ground yarn for cloth, for example, polyester fiber, nylon fiber, rayon fiber, Spun yarns such as acrylic fibers and cotton fibers, blended yarns and filament yarns can be preferably used, and single yarns, compound yarns and twisted yarns can also be used. Furthermore, those yarns which have been subjected to known bulking processes such as false twisting process, air process, crimping process, etc. in order to have a good texture and the like can be used more preferably.

From the viewpoint of weaving density, the yarn (12) has a thickness of 150 to 600 D, preferably a lower limit of 20.
It is preferable to use one having an upper limit value of 0D or more and 450D or less.

The pressing thread (13) twisted around the flower thread is
During weaving, the position of the yarn (12) around the core yarn is stabilized to prevent the yarn (12) from unintentionally extending, and has the same structure as the core yarn (11). The thing of can be used conveniently.

In the present invention, the core yarn (1
1), the flower yarn (12) and the presser yarn (13) are supplied to a well-known plying machine to be ply-twisted to obtain a specially processed yarn (10). At this time, the filament yarn (12) is supplied while overfeeding the core yarn (11), and the filament yarn (12) is twisted around the outer periphery of the core yarn (11) in a spiral winding shape. By supplying the holding thread (13) to the twisted yarn, the holding thread (1
3) is twisted to obtain a specially processed yarn (10).

More specifically, the supply speed of the core yarn (11) to the ply twisting machine is generally about 15 to 20 m / min. However, with respect to the supply speed of the core yarn (11), the flower yarn ( 12)
It is good to set the feeding speed of 16 to 60 m / min,
More preferably, the lower limit speed is set to 16.5 m / min or more and the upper limit speed is set to 40 m / min or less. In other words, the feed rate of the flower yarn (12) is preferably set to 105 to 300% when the feed rate of the core yarn (11) is 100%, more preferably the lower limit value is 110% or more,
It is preferable to set the upper limit value to 200% or less. If this feed rate is too low, sufficient elasticity cannot be imparted to the fabric (moquette) to be produced, and conversely if it is too high, the yarn (12)
Since the bulkiness becomes too high, weaving may not be performed smoothly, and it becomes difficult to obtain a better product appearance, which is not preferable.

The feeding speed of the presser thread (13) is the same as that of the core thread (12) (feed rate to the core thread is 100%).
It is better to set to.

In the present invention, the holding thread (13) is not always necessary, but the flower thread (12) at the time of weaving.
In order to sufficiently secure the positional stability of No. 3, it is preferable to provide the presser thread (13).

On the other hand, in the present invention, at least one of the warp yarn (1a) and the weft yarn (1b) of the ground structure (1) may be composed of the specially processed yarn (10). When only one of them is composed of the specially processed yarn (10), the remaining ground yarn is the same as the above-mentioned flower yarn (12), for example, spun yarn such as polyester fiber, nylon fiber, rayon fiber, acrylic fiber and cotton fiber. Blended yarns and filament yarns can be preferably used, and single yarns, compound yarns, and twisted yarns can also be used. Among them, the 20th to 30th (cotton count) twin yarns made of polyester fibers can be used more preferably.

As the pile yarn (2) forming the pile layer, a well-known pile yarn material can be used without any trouble. For example, a mixed yarn of polyester fiber as a main fiber with nylon fiber, wool fiber, cotton fiber, polyester spun yarn, and the like can be preferably used, and spun yarn of 100% polyester can be used more preferably.

In the present invention, the above-mentioned warp (1a) and weft (1b) and the pile yarn (2) are woven in a warp pile type or the like by a well-known weaving device, and the pile cloth shown in FIG. (Textile intermediate product) is formed. During this weaving, the vertical density of the ground structure is 30 to 100 fibers / inch, more preferably the lower limit value is 40 fibers / inch or more and the upper limit value is 8
It is better to set it to 0 lines / inch or less, and further set the horizontal density to 2
5 to 80 lines / inch, more preferably, the lower limit value of the horizontal density is set to 30 lines / inch or more and the upper limit value is set to 60 lines / inch or less. That is, if the weaving density of the ground weave is too high, weaving becomes difficult, and conversely, if it is too low, the ground weave becomes coarse and the pile tends to come off when the fabric is stretched, which is not preferable.

At the time of weaving, the specially processed yarn (1
No. 0) has the required tensile strength due to the provision of the core yarn (11), so that the weaving process can be performed without any trouble, and the flower yarn (12) does not fully extend.

Woven pile fabric (textile intermediate product)
Is a core yarn (11) and a holding yarn (1) in the ground structure (1).
3) is dissolved or decomposed and removed. For example, when the core yarn (11) and the presser thread (13) made of water-soluble vinylon are used, the core thread (11) and the presser thread (13) are applied by applying moist heat above their melting temperature. Are dissolved at least to the extent that they do not function as fibers. This releases the restraint of the yarn (12) and imparts elasticity to the pile fabric as a whole. The core thread (11) and the presser thread (1
As 3), when another dissolved / decomposed fiber is used, a treatment for dissolving or decomposing the fiber is performed. For example, when the core yarn (11) and the pressing yarn (13) made of rayon fiber are used, the rayon fiber is dissolved using a copper / ammonia solution.

In the present invention, the density of the pile fabric after the dissolution / decomposition treatment is preferably 60 to 110% in both the warp direction and the weft direction, when the density before the dissolution / decomposition process is 100%. More preferably, the lower limit value is 75% or more,
The upper limit is preferably 100% or less. Specifically, the vertical density of the ground structure in the pile fabric after the dissolution / decomposition treatment is 30 to 100 pieces / inch, more preferably the lower limit value is 40 pieces / inch or more and the upper limit value is 80 pieces / inch or less. Further, the horizontal density is 25 to 80 lines / inch, more preferably the lower limit of the horizontal density is 30 lines / inch or more and the upper limit is 60 lines / inch or less.

After the dissolution / decomposition treatment is carried out in this manner, a backing material is impregnated and applied on the back surface of the pile fabric by a known method to form a backing layer (3) as shown in FIG.

In the present invention, the backing material component is not particularly limited, and known ones can be used without any problem, but a backing material having elasticity, for example, to ensure good elasticity as a moquette. It is desirable to use an acrylic, urethane, EVA, vinylidene chloride, or SBR backing material. The coating amount of the backing material is a solid component 20 to 150 g / m ^2, more preferably the lower limit 30 g / m ² or more, the upper limit 120g
/ M ² or less is preferable. That is, if the coating amount is too large, tack (stickiness) may occur, and if it is too small, pile loss may occur, which is not preferable.

The moquette produced as described above has a sufficient elongation, and when it is molded or sewn as a skin material for automobile seats, door trims, console boxes, etc., it fits on the seats, etc. However, a good finish can be obtained.

The present invention is not limited to the production of moquette, but can be applied to any production of general textile products.

[0040]

EXAMPLES Examples related to the present invention and comparative examples for deriving the effects thereof will be described below.

<Example 1>

[Table 1] As shown in Table 1 above, water-soluble vinylon (melting temperature 70
C.) 28D core yarn, 200D / 96f flower yarn made of 1-heater false twisted polyester fiber spun yarn, and a holding yarn having the same structure as the core yarn are twisted by a twisting machine. A special processed yarn of 200 times / m was prepared. At this time, the feeding speed of the core yarn and the pressing yarn is 15 m / min, and the feeding speed of the flower yarn is 20 m / min (feed rate to the core yarn is 13
5%).

Subsequently, a No. 30 (cotton count, the same applies hereinafter) triple spun yarn consisting of 100% polyester fiber spun yarn was used as a pile warp yarn, and a polyester / rayon blended spun yarn (polyester content 85%, rayon content 15%) was used. The No. 30 twin yarn is used as the warp for the ground structure, and the specially processed yarn is used as the weft for the ground structure, the pile density is 23 threads / inch, and the vertical density is 46 threads /
Weaving was carried out at a weaving density of inch and weft density of 44 / inch to prepare a pile fabric for moquette (a woven intermediate product).

Then, the pile fabric was washed with warm water at 90 ° C. for 20 minutes by a Wins dyeing machine to dissolve and remove the core yarn and the holding yarn and dehydrated and dried, and then the roll coater type was applied to the back face of the pile fabric. A backing material consisting of acrylic resin (aqueous emulsion) is used as a solid component in a tenter.
A coating of g / m ^{2 was} applied to produce a moquette. The pile density of this moquette is 25 / inch, and the vertical density is 46 / inc.
It was h and the horizontal density was 44 lines / inch.

According to the moquette thus obtained, JIS
L1095 According to the measuring method of 6.12, the tensile load (kgf) according to the elongation rate (%) was measured. The measurement results are also shown in the same table.

<Example 2> As shown in the same table, except that the core yarn and the presser yarn of the specially processed yarn (weft yarn) made of 56D water-soluble vinylon (melting temperature 30 ° C.) were used. A moquette was produced in the same manner as in, and the same measurement as above was performed.

<Example 3> As shown in the table, 56D core yarn made of water-soluble vinylon (melting temperature 70 ° C.) (feeding rate 15 m / min) and 1-heater false twisted yarn of polyester fiber spun yarn 200D / 96f flower yarn (feed speed 18m / min, feed rate 120% to core yarn)
And a specially processed yarn having a twist number of 200 times / m, which is obtained by ply twisting a core yarn and a pressing yarn having the same configuration (feeding speed 15 m / min).

A moquette was prepared in the same manner as in Example 1 except that the yarn was used as the warp for the ground structure, and the same measurement was performed.

<Example 4> As shown in the same table, a specially-processed yarn in which a core yarn and a holding yarn made of 20D rayon fiber and a flower yarn similar to the above are twisted in the same manner as above is prepared, A pile fabric for moquette (a woven intermediate product) was produced in the same manner as in Example 1 except that the yarn was used as the weft for the base structure.

Subsequently, the pile fabric is dipped in a copper ammonia solution for 20 minutes to dissolve and remove the core yarn and the pressing yarn, and then dried, and then applied to the back face of the pile fabric in the same manner as above. A moquette was prepared and the same measurement as above was performed.

<Comparative Example 1>

[Table 2] As shown in Table 2 above, the same pile warp yarns as described above were used, and as the warp yarn for the ground structure, the No. 30 twin yarn made of polyester / rayon blended yarn (polyester content 65%, rayon content 35%) was used. As a weft for ground structure, a pile fabric was prepared in the same manner as above using No. 30 twin yarn composed of polyester / rayon blended yarn (polyester content 85%, rayon content 15%), and the same as above on the back surface. A backing resin was applied to the to prepare a moquette. Then, the same measurement as above was performed on this moquette. The pile density of this moquette is 24 / inch,
The vertical density was 48 lines / inch and the horizontal density was 44 lines / inch.

<Comparative Example 2> As shown in the same table, a yarn in which 70D spandex was drafted 3.5 times was mixed with polyester / rayon blended yarn (polyester content 85%, rayon content 15%), No. 20 twin yarn. The double-covered textured yarn is used as the weft for the ground structure, and the same warp yarns for the pile and the warp yarn for the ground structure as in Comparative Example 1 are used. The pile density is 21 threads / inch, the vertical density is 42 threads / inch, and the weft density is Four
Weaving was performed at a weaving density of 2 pieces / inch to produce a pile fabric for moquette.

100% of the pile cloth is steamed by a steamer.
After heating for 1 minute at 0 ° C. to shrink, a backing resin was applied to the back surface of the fabric in the same manner as above to prepare a moquette. Then, the same measurement as above was performed on this moquette. The pile density of this moquette was 28 lines / inch, the vertical density was 56 lines / inch, and the horizontal density was 42 lines / inch.

<Evaluation> As shown in Tables 1 to 3 above, Examples 1, 2, 4 in which specially processed yarns peculiar to the present invention were used as weft yarns
It can be seen that in the moquette of No. 3, a sufficient elongation can be obtained under a low load in the weft direction, and in particular, an elongation of 30% or more can be easily obtained under a low load and the elasticity is excellent. Furthermore, in the moquette of Example 3 in which the specially textured yarn unique to the present application was used for both the warp yarn and the weft yarn, a sufficient elongation could be obtained with a low load in both the warp direction and the weft direction. Further, in the moquette of each example, the warp and weft densities hardly changed during weaving and after the product was completed.

On the other hand, the moquette of Comparative Example 1 has a low elongation rate, requires a high load for stretching, and is inferior in stretchability. In addition, in the moquette of Comparative Example 2, when the elongation rate is up to about 30%, it can be stretched with a low load, but since the elongation rate exceeds 30%, a high load is required and the elasticity is insufficient. I know there is. Moreover, the moquette of Comparative Example 2 had a warp density of 42 yarns / inch to 5 after weaving and after completion of the product.
It was greatly changed to 6 / inch.

[0055]

As described above, according to the method for producing a stretchable fabric of the present invention, a fabric having excellent stretchability can be produced, and further, the change in the product density with respect to the weaving density can be reduced, and the product density It is easy to make adjustments, and in turn, to adjust the texture and appearance of the product, and it is possible to manufacture an appropriate product according to demand.

In particular, the production method of the present invention can produce a fabric having excellent stretchability, and is therefore suitable for producing a moquette for a skin material which requires molding of a seat, a door trim, a console box and the like in an automobile.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing details of an example of a moquette manufactured by a manufacturing method of the present invention.

FIG. 2 is a side view schematically showing an example of specially processed yarn used in the manufacturing method of the present invention.

FIG. 3 is a perspective view schematically showing details of a pile fabric manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

 2 ... Pile layer 3 ... Backing layer 10 ... Specially processed yarn 11 ... Core yarn 12 ... Flower yarn 13 ... Pressing yarn

Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display location D06M 15/564 D06M 15/564 17/00 B60R 7/04 C // B60R 7/04 D06M 17/00 K

Claims (7)

[Claims] 1. A step of preparing a specially processed yarn in which a flower yarn is twisted around an outer periphery of a core yarn made of a meltable / degradable fiber, and the specially processed yarn is used for at least one of a warp and a weft. A method for producing a stretchable fabric, comprising the steps of weaving to obtain a woven fabric intermediate product, and a process of dissolving or decomposing the dissolved / degradable fibers in the woven fabric intermediate product to obtain a fabric. 2. The method for producing a stretchable fabric according to claim 1, wherein the specially processed yarn is formed by twisting a holding yarn made of a soluble / degradable fiber around the flower yarn. 3. The method for producing a stretchable fabric according to claim 1, wherein a water-soluble vinylon or rayon fiber is used as the soluble / degradable fiber. 4. The method for producing a stretchable fabric according to claim 1, wherein the flower yarn is made of polyester fiber. 5. The specially-processed yarn is one in which the flower yarn is 1
The method for producing a stretchable fabric according to any one of claims 1 to 4, which comprises overfeeding at a feed rate of 10 to 150% and twisted with a core yarn. 6. The method for producing a stretchable fabric according to claim 1, wherein a pile layer is provided on one surface of the fabric, and a backing layer is formed on the other surface of the fabric. 7. The method for producing a stretchable fabric according to claim 6, wherein the backing layer is made of a stretchable resin of acrylic type, urethane type, ethylene / vinyl acetate copolymer type, vinylidene chloride type, or styrene / butadiene rubber type. .