JPWO2016098325A1 - Fabric with design and method for producing the same - Google Patents

Abstract

Provided is a fabric having a novel design in which an uneven design by embossing is partially formed. A polyurethane resin is applied to the surface of the fabric having a low fineness portion and a high fineness portion having a single fineness higher than that of the low fineness portion on the surface. After drying, the surface is embossed. By performing embossing, the unevenness design part 3 is formed in the non-recessed design part 3 without being provided with the uneven design by the embossing in the high fineness part, and the uneven design part 2 by the embossing is given in the low fineness part. It is formed.

Description

  The present invention relates to a fabric having a partially uneven design and a method for producing the same.

  Embossing is known as one method for imparting an uneven design to a fabric. Embossing is to form a concavo-convex design by pressing a heated mold (called an embossing mold) having a concavo-convex pattern inverted with respect to a desired concavo-convex design (concavo-convex pattern) against the surface of the fabric. Various methods have been proposed (for example, Patent Documents 1 and 2 below). The provision of the uneven design by the conventional embossing gives a uniform uneven design to the entire surface of the fabric, and does not partially form the uneven design by the embossing.

JP 2010-7111 A JP 2010-248668 A

  An object of this invention is to provide the fabric which has a novel design in which the uneven | corrugated design by embossing was partially formed.

  The present invention, firstly, after applying a polyurethane resin to the surface of the fabric having a low fineness part and a high fineness part having a single fiber fineness higher than the low fineness part on the surface, and after drying, The present invention provides a method for producing a fabric with a design partially having an uneven design by embossing, wherein the surface is embossed.

  Secondly, the present invention provides a fabric having a polyurethane resin on a surface portion and having an uneven design portion and a non-recessed design portion on the surface portion, wherein the uneven design portion is more than the non-recessed design portion. Consists of yarns with a low single fineness, the surface is given an uneven design by embossing, the non-concave design part is made of yarn with a single fineness higher than the uneven design part, on the surface The present invention provides a fabric with a design characterized in that an uneven design by embossing is not given.

  ADVANTAGE OF THE INVENTION According to this invention, the fabric which has a novel design in which the uneven | corrugated design was partially formed can be manufactured, without passing through a complicated process.

It is the top view which showed typically an example of the surface design of the fabric which concerns on embodiment. It is a cross-sectional photograph in the uneven | corrugated design part of the fabric which concerns on one Embodiment. It is a cross-sectional photograph in the non-relief design part of the fabric which concerns on one Embodiment. It is a surface photograph in the uneven | corrugated design part of the fabric which concerns on one Embodiment. It is the surface photograph before resin processing of this uneven | corrugated design part. It is a surface photograph in the non-concave design part of the fabric concerning one embodiment. It is a surface photograph before resin processing of this non-concave design part. It is explanatory drawing which shows the knitting structure | tissue which concerns on Example 14.

  Hereinafter, embodiments of the present invention will be described in detail.

  In the method for producing a fabric with a design according to the present invention, a polyurethane resin is applied to the surface of the fabric having a low-fineness portion and a high-fineness portion on the surface, and the surface is embossed after being dried. The low fineness portion having a low single fineness has a small gap between the fibers, and the fibers are fixed to each other by the polyurethane resin, so that formability is improved, and an uneven design can be imparted by embossing. On the other hand, the high fineness portion having a high single fineness has a large gap between the fibers, and is in a state close to point adhesion rather than being fixed to each other by the polyurethane resin. Therefore, in the high fineness part, even if embossing is performed, the uneven design is not given, and the design of the fabric itself can be left. That is, by performing embossing, a non-concave design portion is formed on the high-definition portion without being provided with an uneven design portion by embossing, while an uneven design portion by embossing is provided on the low-fineness portion. Can be formed. Therefore, it is possible to manufacture a fabric having a partially uneven design by embossing without going through a complicated process.

  As the fabric to be treated (that is, fabric or base fabric), a fabric having a low fineness portion and a high fineness portion on the fabric surface is used. The portion where the single fineness of the thread exposed on the fabric surface is low is the low fineness portion, and the portion where the single fineness of the yarn exposed on the fabric surface is high is the high fineness portion. Single fiber fineness refers to the fineness of single fibers or filaments constituting the yarn, and is also referred to as single fiber fineness. The single fineness other than the surface portion such as the back surface of the fabric is not particularly limited, and the low fineness portion and the high fineness portion are concepts used for the surface portion (that is, the surface layer portion) of the fabric. Here, “high” and “low” in the high fineness portion and the low fineness portion are intended to express the relationship of the relative fineness between the two fineness portions. That is, it means that the high fineness portion has a single fineness higher than that of the low fineness portion (in other words, the low fineness portion has a single fineness lower than that of the high fineness portion).

  A low fineness part is a part comprised by the thread | yarn whose single fineness is lower than a high fineness part in the surface part of a fabric, and this part turns into an uneven | corrugated design part by embossing. In the present invention, it is not necessary that all the yarns constituting the low fineness portion have a single fineness lower than the yarn constituting the high fineness portion, and the yarn mainly constituting the low fineness portion has the high fineness portion. It is only necessary that the single fineness is lower than that of the main yarn. Here, “mainly constituted” means that 70% or more (volume ratio) of the yarn exposed on the fabric surface is constituted, and more preferably, 80% or more. The low fineness portion preferably includes a yarn having a single fineness of 1.5 dtex or less, that is, the single fineness of the yarn constituting the low fineness portion is preferably 1.5 dtex or less. In other words, in the low fineness portion, it is preferable that the yarn exposed mainly on the surface has a single fineness of 1.5 dtex or less. By setting the single fineness of the yarn constituting the low fineness portion to 1.5 dtex or less, the gap between the fibers constituting the low fineness portion can be reduced, and the fixing effect of the fibers by the polyurethane resin can be enhanced. The formability of the uneven design by embossing can be enhanced. The single fineness of the yarn constituting the low fineness portion is preferably 1.0 dtex or less, more preferably 0.7 dtex or less. The lower limit of the single fineness is not particularly limited, but is preferably 0.1 dtex or more.

  The high fineness portion is a portion composed of yarn having a single fineness higher than that of the low fineness portion in the surface portion of the fabric, and this portion becomes a non-concave design portion. The high fineness portion preferably includes a yarn having a single fineness higher than 1.5 dtex, that is, the single fineness of the yarn constituting the high fineness portion is preferably higher than 1.5 dtex. In other words, in the high fineness portion, it is preferable that the yarn exposed on the surface mainly has a single fineness of more than 1.5 dtex. By increasing the single fineness of the yarn constituting the high-fineness portion to be higher than 1.5 dtex, the gap between the fibers constituting the high-fineness portion can be increased, and the fixing effect of the fibers by the polyurethane resin can be reduced. it can. Therefore, the uneven design is not easily formed by embossing. In order to more effectively suppress shaping of the uneven design in the high fineness portion, the single fineness of the yarn constituting the high fineness portion is preferably 2.3 dtex or more, more preferably 2.5 dtex or more. The upper limit of the single fineness is not particularly limited, but is preferably 2000 dtex or less if the yarn is a monofilament, and preferably 10 dtex or less if the yarn is a multifilament.

  The difference in single fineness between the low fineness portion and the high fineness portion is preferably 0.4 dtex or more, more preferably 0.5 dtex or more, further 1.0 dtex or more, and further preferably 2.0 dtex or more. is there. Thereby, a design can be changed more clearly between an uneven | corrugated design part and a non-uneven | corrugated design part.

  The fineness of the yarn constituting the low fineness portion (that is, the total fineness, also referred to as yarn fineness) is preferably set to be equal to or greater than the total fineness of the yarn constituting the high fineness portion. Thereby, the space | interval between fibers can be made small by the fine fiber with a low single fineness being densely filled in a low fineness part.

  The fabric having a low-fineness portion and a high-fineness portion on the surface portion as described above may be a woven fabric or a knitted fabric, and may be appropriately selected depending on the application. Further, the method for forming the low fineness portion and the high fineness portion is not particularly limited.

  For example, in the case of a woven fabric, a warp and weft may be combined using a warp and weft structure by using a yarn having a low single fineness for one of the warp and weft and using a yarn having a high single fineness for the other. Accordingly, the low fineness portion where the yarn having a low single fineness is mainly exposed on the surface, and the high fineness portion where the yarn having a high single fineness is mainly exposed on the surface can be provided by the transverberation portion and the weft redness portion. .

  Similarly, in a structure other than this, in the warp and weft, a yarn arrangement of a yarn having a low single fineness and a yarn having a high single fineness, and a low fineness portion in which the yarn having a low singleness is mainly exposed on the surface, It is possible to provide a high-definition portion where high-definition yarns are mainly exposed on the surface.

  Also in the case of knitted fabric, the composition of the low-fineness portion and the high-fineness portion is the same as in the woven fabric, by knitting a yarn having a low single fineness and a yarn having a high single fineness by combining a knitting structure and a yarn arrangement It is possible to provide a low fineness portion where the yarn having a low single fineness is mainly exposed on the surface and a high fineness portion where the yarn having a high single fineness is mainly exposed on the surface.

When the fabric to be treated is a woven fabric, the total fineness per unit volume of 1 mm ³ is preferably 2500 to 5800 dtex. More preferably, it is 3000-5800 dtex, More preferably, it is 3500-5800 dtex. By setting this value to 2500 dtex or more, the voids between the fibers can be reduced, and the formability of the uneven design by embossing can be improved. Moreover, favorable weaving property is securable by setting it as 5800 dtex or less.

The total fineness per unit volume of 1 mm ³ is calculated as follows. The product of warp density (line / 25.4mm), warp fineness (fineness of yarn) (dtex) and 25.4mm, width direction 25.4mm x length direction 25.4mm x fabric The sum of the fineness in the volume of thickness (mm) is calculated. Here, in the above product, the warp yarn is multiplied by 25.4 mm, assuming that it extends straight in the length direction of the raw machine. The sum of the fineness of the weft is calculated in the same manner as the warp, and the sum of the sum of the fineness of the warp and the sum of the fineness of the weft is calculated. The quotient of the calculated value and volume (width direction × length direction × fabric thickness) is calculated and taken as the total fineness per 1 mm ³ . The above formula is appropriately changed in consideration of thread removal and texture. For example, if the thread removal is 1 in 3 out (that is, an arrangement of one thread holder and three thread cutters), it is further multiplied by 1/4.

Specifically, it is calculated | required by the following formula | equation.
Total fineness per unit volume 1 mm ³ = (warp density × warp fineness (yarn fineness) × 25.4 + weft density × weft fineness (yarn fineness) × 25.4) / (25.4 × 25. 4 x fabric thickness (mm))

When the fabric to be treated is a knitted fabric, the total fineness per unit volume of 1 mm ³ is preferably 1000 to 5800 dtex. More preferably, it is 1200-5800 dtex, More preferably, it is 1500-5800 dtex. By setting this value to 1000 dtex or more, the voids between the fibers can be reduced, and the formability of the uneven design by embossing can be improved. Moreover, favorable knitting property is securable by setting it as 5800 dtex or less.

In addition, the sum total of the fineness per volume 1mm < ³ > in the case of a knitted fabric is calculated by the following. By the product of the double of the course density, the fineness of the yarn and 25.4 mm, the volume in the width direction (25.4 mm) x length direction (25.4 mm) x fabric thickness (mm) with respect to the length direction of the raw machine The total fineness is calculated. Here, when the cross section perpendicular to the length direction of the raw machine is viewed, two cross sections can be seen in one loop. Further, it is assumed that the horizontal section continues 25.4 mm in the width direction. The quotient of the calculated value and volume (width direction × length direction × fabric thickness) is calculated and taken as the total fineness per 1 mm ³ . When the structure is multiple, the yarn fineness in the volume of raw machine width direction (25.4 mm) x raw machine length direction (25.4 mm) x fabric thickness (mm) was calculated for each yarn constituting each structure. Thereafter, the sum is calculated, and the quotient of the total value and the volume is calculated to obtain the total fineness per unit volume of 1 mm ³ . The above formula is appropriately changed in consideration of thread removal and texture. For example, if the thread removal is 1 in 3 out, it is further multiplied by 1/4.

Specifically, it is calculated | required by the following formula | equation.
Total fineness per 1 mm ³ unit volume (for tricots and circular knitting)
= (Total of fineness of each thread ^{* 1} x course density x 2 x 25.4) / (25.4 x 25.4 x fabric thickness (mm))
* 1: For tricots, the sum of the fineness of the front, middle, and back yarns. For circular knitting, the sum of the fineness of the front, splicing, and back yarns.

Total fineness per unit volume of 1 mm ³ (in the case of double raschel opening)
= {(Total fineness of each yarn + total fineness of each pile yarn) × course density × 2 × 25.4} / (25.4 × 25.4 × fabric thickness (mm))

The total fineness per unit volume 1 mm ³ (when a double Russell HiHiraku anti goods)
= {(Total fineness of each yarn + total fineness of each connecting yarn × 2) × course density × 2 × 25.4} / (25.4 × 25.4 × fabric thickness (mm))

  The material of the fibers constituting the fabric to be treated is not particularly limited, and known fibers such as natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers can be used. These fibers can be blended, mixed, or mixed. Two or more kinds may be used in combination by a method such as twisting, union weaving or union knitting. From the viewpoint of the formability of the uneven design and the durability, thermoplastic fibers are preferred. Examples of the thermoplastic fiber include synthetic fibers such as polyester, polypropylene, and nylon, and semi-synthetic fibers such as acetate and triacetate. These can be used alone or in combination of two or more. Of these, polyester is more preferable and polyethylene terephthalate is particularly preferable because of its excellent physical properties.

  The form of the yarn constituting the fabric may be a spun yarn (short fiber yarn), a multifilament yarn, or a monofilament yarn (hereinafter, long fiber yarn), and a long and short combination of long fibers and short fibers. It may be a composite spun yarn. The multifilament yarn may be twisted as necessary, or may be subjected to processing such as false twisting or fluid disturbance treatment.

  Further, the fabric may be subjected to pretreatment such as raising, dyeing, presetting, and scouring as necessary. When raising, it is preferable to cut and raise the yarn having a low single fineness exposed on the surface in the low fineness portion, since the uneven design by embossing can be more easily shaped.

  The polyurethane resin used in the present invention is not particularly limited, and examples thereof include polyether-based, polyester-based, and polycarbonate-based polyurethane resins. Of these, polyester polyurethane resins are preferably used from the viewpoint of texture, and polycarbonate polyurethane resins are preferably used from the viewpoint of durability, particularly wear resistance.

  The softening temperature of the polyurethane resin is preferably 100 to 200 ° C. When the softening temperature is 100 ° C. or higher, the resin can be hardly dissolved even when used under conditions such as a vehicle interior material that is left at a high temperature for a long time. When the softening temperature is 200 ° C. or lower, it is not necessary to set the embossing roll to an excessively high temperature when shaping the uneven design, and the base fabric where the polyurethane resin is not applied is prevented from becoming coarse. be able to. The softening temperature is measured by differential scanning calorimetry using a DSC thermal analyzer.

The polyurethane resin is applied to the entire surface of the fabric having the above-described low-fineness portion and high-fineness portion on the surface. The amount of polyurethane resin applied varies depending on the configuration of the fabric to be treated, such as density and fineness, but is preferably about 1 to 200 g / m ² , more preferably 5 to 150 g / m ² with respect to the fabric. ² and more preferably 10 to 100 g / m ² . In the fabric with a design according to the present embodiment, the polyurethane resin penetrates between the fibers in at least the surface portion (surface layer portion) of the fabric to form the fabric surface together with the fibers, and the polyurethane resin like a synthetic leather with a silver surface. A single skin layer is not formed on the entire surface of the fabric. In addition, the provision amount of a polyurethane resin converts the provision amount in the part to which a polyurethane resin is provided into the provision amount per square meter, and is a value in solid weight after drying.

  More specifically, a treatment liquid containing a polyurethane resin is applied to one surface of the fabric. The treatment liquid contains at least a polyurethane resin and a medium for dispersing the polyurethane resin, for example, water. If necessary, additives such as coloring materials (dyes, pigments, metal powders), thickeners, and the like. May be included. The method for applying the treatment liquid is not particularly limited, and examples thereof include screen printing, rotary printing, and inkjet printing. Further, when the fabric has irregularities, a reverse coater, a comma coater, or the like can be used.

  Next, the polyurethane resin is dried and solidified. The drying may be performed to such an extent that the medium does not remain, and the conditions are not particularly limited. What is necessary is just to set suitably in consideration of the boiling point of a medium and production efficiency.

  Thus, after apply | coating a polyurethane resin to the surface part of a fabric and drying, embossing is performed to the whole surface. Specifically, for example, the polyurethane resin on the surface of the fabric is softened by passing through an embossing roll having a temperature of 100 to 160 ° C. and a pressure (linear pressure) of 490 to 1960 N / cm. The surface of the embossing roll is engraved with a concavo-convex pattern in which the desired concavo-convex pattern and the concavo-convex pattern are reversed. The temperature of the embossing roll is set in consideration of the softening temperature of the polyurethane resin, the fiber material constituting the fabric, the required durability, and the like.

  The fabric after the shaping process may be heat-treated in order to soften the texture. The heat treatment is preferably performed at 100 to 150 ° C. for 30 seconds to 3 minutes.

  As described above, a design-equipped fabric having a partially uneven design can be obtained. The fabric with a design according to the embodiment has a polyurethane resin on the surface portion, and has an uneven design portion and a non-recessed design portion on the surface portion. The polyurethane resin is present along with the fibers over the entire fabric surface, and the fabric surface is formed of the polyurethane resin and the fibers. The polyurethane resin permeates between fibers in at least the surface portion of the fabric in the thickness direction, and the polyurethane resin permeation portion is formed on at least the surface portion of the fabric.

  Drawing 1 shows typically an example of the surface design of the cloth with a design concerning an embodiment. The fabric 1 with a design has a concavo-convex design portion 2 provided with a concavo-convex design composed of an embossed pattern and a non-concave design portion 3 not provided with a concavo-convex design composed of an embossed pattern on the surface portion. The uneven design portion 2 and the non-recessed design portion 3 are repeatedly provided in a predetermined pattern over the entire surface of the fabric 1 to form a repetitive pattern. In this example, the uneven design portion 3 is uneven around the hexagonal non-recessed design portion 3. The tortoiseshell pattern which the design part 2 surrounds is comprised. The concave / convex design portion 2 and the non-concave design portion 3 may be configured opposite to the configuration shown in FIG. 1, and their shape, number and arrangement are not particularly limited, and various changes can be made. .

  The concavo-convex design portion is formed by the low-fineness portion, and the non-concave design portion is formed by the high-fineness portion. Therefore, the concavo-convex design portion is composed of yarn having a single fineness lower than that of the non-concave design portion, and the non-concave design portion is composed of yarn having a single fineness higher than that of the concavo-convex design portion.

  In the concavo-convex design portion, adjacent fibers are firmly fixed to each other by a polyurethane resin as compared with the non-concave design portion, and thus the concavo-convex design by embossing is given to the surface. In detail, since the fiber which comprises a low fineness part is thin, since the space between fibers is small and the polyurethane resin is easily filled in the said space, it will be in the state which fibers adhered by polyurethane resin (refer FIG. 2). . Therefore, it is easy to form with a polyurethane resin at the time of embossing, Therefore, an uneven | corrugated design can be provided by embossing. The uneven design by embossing is not particularly limited, and a desired uneven shape such as a leather-like texture pattern or a geometric pattern may be provided.

  On the other hand, in the non-concave design portion, adjacent fibers are fixed more loosely than the concave-convex design portion with polyurethane resin, and therefore the surface is not provided with an uneven design by embossing. In detail, since the fiber which comprises a high fineness part is thick, the space between fibers is large, and when it is the same resin amount, the space | gap which is not filled with a polyurethane resin will become larger than a low fineness part. Therefore, rather than the fibers being fixed to each other by the polyurethane resin, adjacent fibers are point-bonded to each other by the polyurethane resin (see FIG. 3). Therefore, even if embossing is performed, the uneven design is not given, and the design of the fabric itself can be left. That is, the non-concave design portion is a portion to which an uneven design by embossing is not given, and if it is an uneven design not by embossing, the uneven design formed by the yarn by the structure on the woven fabric or knitted fabric You may have.

  In this embodiment, the penetration thickness of the polyurethane resin in the low-fineness portion (that is, the uneven design portion) is 40 to 400 μm, the polyurethane resin filling rate is 10 to 55%, and the fiber filling rate is 45 to 80%. Thus, it is preferable to apply a polyurethane resin.

  That is, the penetration thickness of the polyurethane resin is preferably in the range of 40 to 400 μm, more preferably 40 to 330 μm, still more preferably 40 to 260 μm, and particularly preferably 50 to 400 μm in the uneven design portion. 200 μm. By setting to such a range, the moldability by embossing can be improved. Here, the penetration thickness of the polyurethane resin is measured by measuring the vertical section from the fabric surface to the lower end of penetration of the polyurethane resin at an arbitrary 10 locations by photographing a vertical section of the polyurethane resin penetration portion with a microscope. And it calculates | requires by calculating an average value.

  As described above, the polyurethane resin penetrates between fibers in at least the surface portion of the fabric, and may penetrate throughout the entire fabric thickness. From the viewpoint of texture, it is preferable that the polyurethane resin does not penetrate the entire fabric thickness. That is, it is preferable that a non-penetrating part exists under the polyurethane resin-penetrating part. Specifically, in the uneven design part, the ratio of the penetration thickness of the polyurethane resin to the thickness of the fabric with a design may be 5 to 25% or 10 to 20%. The penetration thickness of the polyurethane resin in the non-concave design portion is not particularly limited, but is usually larger than the penetration thickness in the concave-convex design portion due to a large gap between fibers, and may be, for example, 100 to 500 μm. 130-400 μm or 150-300 μm. In the non-concave design portion, the ratio of the penetration thickness of the polyurethane resin to the thickness of the fabric with design is preferably larger than the ratio of the penetration thickness in the uneven design portion, for example, 21 to 55%. It may be -55% or 30-55%. Here, the thickness of the fabric with a design is not particularly limited, and may be, for example, 0.2 to 3.0 mm (that is, 200 to 3000 μm) or 0.3 to 2.8 mm. In addition, the numerical range about the ratio of these penetration thickness and the thickness of the cloth with a design is an illustration about the cloth except the non-opening product of a double raschel.

  Moreover, it is preferable that the filling rate of a polyurethane resin is in the range of 10-55% in an uneven | corrugated design part, More preferably, it is 15-50%, More preferably, it is 20-45%. When the filling rate of the polyurethane resin is 10% or more, the moldability by embossing can be improved. Further, when the filling rate is 55% or less, the bending resistance can be improved.

Here, the filling rate of the polyurethane resin is a ratio occupied by the polyurethane resin in the polyurethane resin permeation portion (the portion where the polyurethane resin permeates between the fibers), and is obtained as follows. That is, it calculates | requires by a following formula from the filling rate and porosity of the below-mentioned fiber.
Filling ratio of polyurethane resin (%) = 100− (filling ratio of fiber + void ratio)

  Moreover, it is preferable that it is in the range of 45-80% in an uneven | corrugated design part, The filling rate of a fiber is more preferably 50-80%, More preferably, it is 55-80%. When the filling factor of the fibers is 45% or more, the gap between the fibers can be reduced, the adhesion between the fibers can be increased, and the wear resistance can be improved. Further, when the fiber filling rate is 80% or less, the bending resistance can be improved. In addition, although the filling rate of the fiber in a non-concave design part is not specifically limited, It is preferable that it is 50% or less, More preferably, it is 20 to 45%, Usually, the single fiber degree of the fiber to comprise is high, and between fibers Because of the large gap, the filling rate of the fiber in the uneven design portion is smaller.

Here, the filling rate of the fiber is a ratio of the fiber in the polyurethane resin permeation portion, and is obtained as follows. That is, the number of yarn cross-sections (n) in the measurement area where the vertical cross section of the polyurethane resin infiltrated portion is read with a microscope, measured with a width of 100 μm in the horizontal direction and the infiltrated thickness of the polyurethane resin in the vertical direction. And the fiber filling rate is obtained by the following formula. The diameter R (μm) of the yarn is obtained by measuring and averaging the diameters in the vertical and horizontal directions of the cross-sections of arbitrary five yarns. Moreover, the filling rate of the fiber is an average value of the filling rates calculated by the following formula at arbitrary five locations.
Fiber filling rate (%) = (78.5 × R ² × n) ÷ (100 × polyurethane resin penetration thickness (μm))

  In the present embodiment, the polyurethane resin is used so that the porosity in the high-fineness portion (that is, the non-concave design portion) is 10% or more and is higher than the porosity in the low-fineness portion (that is, the uneven design portion). It is preferable that it is provided. That is, in the non-concave design portion, the porosity is preferably 10% or more, and more preferably 15% or more. When the porosity is 10% or more, the uneven design by embossing is hardly formed, and it becomes easier to change the design more clearly between the uneven design portion. The upper limit of the porosity in the non-concave design portion is not particularly limited, but is usually 30% or less, more preferably 20% or less. The porosity in the concavo-convex design portion is lower than the porosity in the non-concave design portion, and is not particularly limited, but is preferably less than 10%, more preferably 7% or less.

  Here, the porosity is a ratio occupied by the void portion in the polyurethane resin permeation portion, and is obtained as follows. In other words, in the measurement area where the horizontal cross section of 100 μm width and the vertical direction of the polyurethane resin penetration thickness are read with a scanner, a photograph taken of a vertical cross section of the polyurethane resin penetration section with a microscope, the void portion and other portions Is binarized, and the ratio of the void portion in the polyurethane resin permeation portion is calculated. The porosity is an average value of the porosity calculated at any five locations.

  In the present embodiment, the ratio of the fiber and the polyurethane resin (fiber / polyurethane resin) in the uneven design portion is preferably 1.0 or more, more preferably 1.25 or more. By setting this ratio to 1.0 or more, the number of fibers per polyurethane resin is increased, the fixing effect by the polyurethane resin is enhanced, the formability of the uneven design by embossing is improved, and the durability is improved. be able to. This ratio is obtained by calculating the respective areas by the product of the filling ratio of the fiber and polyurethane resin calculated above and the measurement area, and calculating the quotient of the area of the fiber and the area of the polyurethane resin. In addition, the ratio of the fiber and the polyurethane resin (fiber / polyurethane resin) in the non-concave design portion is smaller than the ratio in the uneven design portion, preferably less than 1.0, and more preferably less than 0.8.

In the present embodiment, the sum of the outer peripheral lengths of the fiber cross sections in the uneven design portion is preferably 1500 μm or more, more preferably 2000 μm or more per unit area of 10,000 μm ² . If the sum of the outer peripheral lengths of the fiber cross section is 1500 μm or more, the adhesion between the polyurethane resin and the fiber is improved, the compression recovery force of the fiber is suppressed, and the moldability of the uneven design by embossing can be improved. it can. This is presumably because the larger the sum of the outer peripheral lengths, the more fibers (filaments) having a small single fineness, the smaller the gaps between the fibers, and the easier the polyurethane resin and the fibers are fixed. Further, the fact that there are many fibers having a small single fineness is considered to be because the surface area of the polyurethane resin is increased because the surface area is large with respect to the total fineness, and it is easy to fix. The upper limit of the sum of the outer peripheral lengths of the fiber cross sections is not particularly limited, and may be, for example, 9000 μm or less, or 6000 μm or less. In addition, it is preferable that the sum of the outer peripheral length of the fiber cross section in a non-concave design part is smaller than the value in an uneven design part.

Here, the sum of the outer peripheral lengths of the fiber cross sections is obtained as follows. That is, the number of yarn cross-sections (n) in the measurement area where the vertical cross section of the polyurethane resin infiltrated portion is read with a microscope, measured with a width of 100 μm in the horizontal direction and the infiltrated thickness of the polyurethane resin in the vertical direction. And the sum of the outer perimeters of the fiber cross section is determined by the following formula. The diameter R (μm) of the yarn is obtained by measuring and averaging the diameters in the vertical and horizontal directions of the cross-sections of arbitrary five yarns. Further, the sum of the outer peripheral lengths of the fiber cross-sections is an average value of the sum of the outer peripheral lengths calculated by the following formula at arbitrary five locations.
Sum of outer peripheral lengths of fiber cross section (μm) = (31400 × R × n) ÷ (100 × polyurethane resin penetration thickness (μm))

  FIG. 2 is a cross-sectional view of a rugged design portion of a fabric with a design according to an embodiment. A vertical cross section of a polyurethane resin infiltrating portion on the fabric surface side is a microscope (manufactured by Keyence Corporation, Digital HF microscope). VH-8000, the same below). The part enclosed by the rectangular frame in a photograph is a measurement range at the time of measuring a filling rate and a porosity, A measurement width | variety is 100 micrometers and height is the penetration thickness of a polyurethane resin. FIG. 3 is a photograph of a vertical cross section taken at a non-recessed design portion of the fabric of the same as above with a microscope. As in FIG. 2, the portion surrounded by a rectangular frame in the photograph measures the filling rate and the void ratio. The measurement range is 100 μm, and the height is the penetration thickness of the polyurethane resin. When measuring the penetration thickness, filling rate, porosity, etc. using these photographs, in order to reduce the variation at the measurement position, in the yarn portion where the fibers are agglomerated (that is, the yarn and Calculate the average value of 5 or 10 random samples (excluding the boundary of the yarn).

  FIG. 4 is a surface photograph of the concavo-convex design portion (single fineness: 0.6 dtex) of the fabric with a design according to one embodiment, and FIG. 5 is a surface photograph before the resin processing, both of which are 100 with a microscope. The picture was taken at double magnification. In the low fineness portion, a large number of filaments clearly appear before the resin processing shown in FIG. 5, whereas there is a clear change in the surface shape after the resin processing and embossing shown in FIG. Is not clearly visible.

  FIG. 6 is a surface photograph of the non-recessed design portion (single fineness: 7.5 dtex) of the fabric described above, and FIG. 7 is a surface photograph before resin processing, both of which are magnified 100 times with a microscope. It was taken. In the high fineness portion, the surface shape hardly changes between before the resin processing shown in FIG. 7 and after the resin processing and embossing shown in FIG.

  According to the present embodiment configured as described above, it is possible to manufacture a fabric having an uneven design by embossing partially without obtaining a complicated process, and leaving the design of the fabric itself in other portions. A fabric having an unprecedented special design can be manufactured at low cost.

  The use of the fabric with a design of the present invention is not particularly limited, and can be used in various fields such as vehicle interior materials, interior materials, clothing, bags, and the like.

[Evaluation method]
(1) Formability About the product which embossed using the embossing rolls A, B, and C which have the following uneven | corrugated shape, the uneven | corrugated design part and the non-protrusion design part were confirmed visually, and it evaluated according to the following evaluation criteria. . For the following concave shape, the handle interval is the distance between the vertices of adjacent convex portions, and the inclination angle is the straight line connecting the highest level of the convex portion and the lowest level of the concave portion and the tangent at the highest level of the convex portion. This is the angle formed by
Embossing roll A: recess width 800 μm, recess depth maximum value 150 μm, pattern spacing 2000 μm, vertical cross-sectional shape of irregularities; corrugated, inclination angle 5-20 degrees, leather wrinkle pattern Embossing roll B: recess width 1200 μm , Maximum depth of recesses 250 μm, pattern spacing 5000 μm, vertical cross-sectional shape of corrugations; corrugated, tilt angle 10-30 degrees, leather wrinkle pattern Embossing roll C: recess width 1500 μm, maximum recess depth 450 μm, pattern spacing 10000 μm, vertical uneven cross-sectional shape; trapezoidal shape, line pattern (evaluation criteria)
1: All the uneven shapes of A, B, C are clearly shaped 2: The uneven shape of A is unclear, but the uneven shapes of B, C are clearly shaped 3: A The uneven shape of B is unclear, but the uneven shape of C is clearly shaped 4: All the uneven shapes of A, B, and C are unclear

(2) Designability After evaluating the moldability, the uneven design portion and the non-recessed design portion of the product were visually observed and evaluated according to the following evaluation criteria.
(Evaluation criteria)
1: Since the uneven design part is clearly embossed by embossing, and the uneven shape part is not seen in the non-recessed design part, two types of designs are clearly obtained. The concavo-convex shape by embossing is clearly formed on the part, but the concavo-convex shape by embossing can be seen though it is unclear also in the non-concave design part. Or although the uneven | corrugated shape is not seen in a non-uneven | corrugated design part, the uneven | corrugated shape of an uneven | corrugated design part is unclear. Therefore, two types of designs have been obtained although lacking in clarity. 3: The uneven shape is clearly shaped in both, or both are unclear and two types of designs are not obtained. .

[Example 1]
As warps, 178 dtex / 24f polyethylene terephthalate false twisted yarn (single fineness: 7.42 dtex) is used, and as weft, 333 dtex / 288f polyethylene terephthalate false twisted yarn (single fineness: 1.16 dtex) is used. The design part was woven with a 12-sheet weaver, and the non-design part was a 12-sheet suzuki structure.

Next, from a weaving end direction and a weaving start direction at a cloth roller speed of 2.5 MPa and a cloth speed of 12 m / min by a needle cloth raising machine equipped with a needle cloth roll having twelve pile rollers and twelve counter pile rollers. Raising was performed three times alternately, and raising was mainly performed so that the surface of the weft was fluffed. Subsequently, it heat-processed for 1 minute at 150 degreeC with the heat setter, and was finished. The resulting fabric had a warp density of 184 pieces / 25.4 mm, a weft density of 88 pieces / 25.4 mm, and a total fineness per unit volume of 1 mm ³ of 4072 dtex.

Next, a polyurethane resin solution (solid content 28% by mass) was applied to the entire surface with a knife coater at a cloth speed of 8 m / min. Clearance conditions were set so that the amount of polyurethane resin applied was 25 g / m ² by weight after drying. After applying the polyurethane resin solution, the polyurethane resin solution was dried with an 80 ° C. dryer for 5 minutes. As the polyurethane resin solution, a polyurethane resin “RYUDTE-W Binder UF6025” (manufactured by DIC Corporation, softening temperature = 120 ° C.) was used.

  Subsequently, embossing was performed with an embossing machine at a roll temperature of 120 ° C., a roll pressure of 1960 N / cm, and a cloth speed of 3 m / min. The embossing roll used the above-mentioned three types of rolls AC. Subsequently, it heat-processed at 130 degreeC with the heat setter for 1 minute, and was finished.

The obtained fabric has an embossed uneven design only on the portion where the weft is fuzzy. The polyurethane resin penetration thickness in the uneven design portion (weft satin portion) is 78 μm, the fiber filling rate is 56.2%, The polyurethane resin filling rate is 40.7%, the porosity is 3.1%, the fiber to polyurethane resin ratio (fiber / polyurethane resin) is 1.38, and the sum of the outer perimeters of the fiber cross section per unit area of 10000 μm ² is 2196 μm. Further, the penetration depth of the polyurethane resin in the non-concave design portion (transverse satin portion) is 199 μm, the fiber filling rate is 36.3%, the polyurethane resin filling rate is 46.8%, the porosity is 16.9%, and the fibers and polyurethane The resin ratio (fiber / polyurethane resin) was 0.78, and the sum of the outer peripheral lengths of the fiber cross section per unit area of 10000 μm ² was 1682 μm. The thickness of the fabric with design was 600 μm.

  The evaluation results are shown in Table 1. According to Example 1, the uneven design portion having a leather-like texture pattern and the non-recessed design portion having a design based on the woven structure of the fabric itself have a unique design repeated in a predetermined pattern over the entire fabric. A fabric was obtained.

[Examples 2 to 10, Comparative Example 1]
Fabrics of Examples 2 to 10 and Comparative Example 1 were produced in the same manner as in Example 1 except that the configurations and densities of the warp and weft were changed as shown in Table 1.

  The evaluation results are as shown in Table 1, and in Comparative Example 1 in which the yarns having the same single fineness are used for the warp and the weft, the concavo-convex shape by embossing is clearly shaped in both the weft satin part and the warp satin part. Two types of designs were not obtained, and the design was inferior. On the other hand, if it is Examples 1-10, two types of designs of the uneven | corrugated design part to which the uneven | corrugated design by embossing was provided, and the non-concave design part with the design by the woven structure | tissue of the fabric itself were made into the fabric surface. A fabric having the following was obtained. In particular, in the fabrics of Examples 1 and 3, the difference between the concavo-convex design portion and the non-concave design portion was clear, and the design properties were particularly excellent. Here, in Example 6 and Example 8, contrary to the other examples, the warp red part was an uneven design part and the weft red part was a non-concave design part.

  In Example 7, the fiber filling rate in the concavo-convex design portion was low, and the wear resistance was inferior to that in Example 1. In Example 8, the fiber filling rate in the concavo-convex design portion was high, and the bending resistance was inferior to that in Example 1. In Example 10, since the void ratio in the non-concave design portion was low, and the uneven shape by embossing was slightly seen in the non-concave design portion, the design property was inferior to that in Example 1, and Example 1 Compared to, the wear resistance was also inferior.

  Here, the wear resistance was measured according to the wear strength C method (Taber method) of JIS L1096 8.19.3 (conditions: wear wheel CS-10, load 4.9 N, wear number 1000 times). Then, the specimen after the abrasion test was observed and evaluated from the viewpoint of whether the appearance was not changed or whether the uneven design was unclear or disappeared.

  In addition, for bending resistance, three test pieces were taken from each of the vertical and horizontal directions with a width of 40 mm and a length of 70 mm, and each test piece was placed in the length direction so that the surface was on the outside. Bending in two and using a dematcher type bending tester (manufactured by Ueshima Seisakusho Co., Ltd.) at a grip interval of 30 ± 0.2 mm, a stroke of 15 mm, and a speed of 100 times / minute, 30000 times in an environment of −10 ° C. A bending resistance test was performed. The appearance of the test piece after the bending test was observed and evaluated based on the degree of appearance change.

[Example 11]
According to the structure shown in Table 3 using each polyethylene terephthalate yarn shown in Table 2 below, a striped tricot knitted fabric with a portion composed of L2 and L3 (14 wells) and a portion composed of L4 (12 wells) Produced. Next, a polyurethane resin solution (solid content 28% by mass) was applied to the sinker loop surface (L2, L3, L4) at a cloth speed of 5 m / min and a roll rotation speed of 12 m / min by a reverse coater. Roll rotation speed conditions were set so that the polyurethane resin coating amount was 25 g / m ² by weight after drying. After applying the polyurethane resin solution, the polyurethane resin solution was dried with an 80 ° C. dryer for 5 minutes. As the polyurethane resin solution, a polyurethane resin “RYUDTE-W Binder UF6025” (manufactured by DIC Corporation) was used.

  Subsequently, embossing was performed with an embossing machine at a roll temperature of 160 ° C., a roll pressure of 490 N / cm, and a cloth speed of 3 m / min. The embossing roll used the above-mentioned three types of rolls AC. Subsequently, it heat-processed at 130 degreeC with the heat setter for 1 minute, and was finished.

  The evaluation results are shown in Table 4. In the obtained fabric, the part formed with the front yarn became the uneven design part, and the uneven design by embossing was given. Moreover, the part formed with the middle yarn became a non-concave design part, and the uneven design by embossing was not given.

[Examples 12 to 14]
Fabrics of Examples 12 to 14 were produced in the same manner as in Example 11 except that the configuration and structure of each polyethylene terephthalate yarn were changed as shown in Tables 2 and 3. The evaluation results are as shown in Table 4.

  In Example 12, the double raschel knitted fabric was opened, and the polyurethane resin solution was applied to the pile surface of the stripe pattern composed of the portion composed of L3 (10 wells) and the portion composed of L4 (10 wells). In the obtained fabric, a portion formed by the yarn guided by the heel L3 was an uneven design portion, and an uneven design by embossing was given. Moreover, the part formed with the thread | yarn guided with the heel L4 became a non-concave design part, and the uneven design by embossing was not attached | subjected.

  In Example 13, the double raschel knitted fabric was not opened, and polyurethane was applied to the surface structure (L4, L5) of the stripe pattern composed of the portion composed of L4 (7 well) and the portion composed of L5 (7 well). A resin solution was applied. In the obtained fabric, the portion formed by the yarn guided by the heel L4 was an uneven design portion, and an uneven design by embossing was given. Moreover, the part formed with the thread | yarn guided by the heel L5 became a non-concave design part, and the uneven design by embossing was not attached | subjected.

  In Example 14, the polyurethane resin solution was applied to the surface of the border pattern composed of the portion composed of the front yarn 1 (14 course) and the portion composed of the front yarn 2 (14 course) of the double jersey knitted fabric. In the obtained fabric, the part formed with the surface yarn 1 became an uneven design part, and the uneven design by embossing was given. Moreover, the part formed with the surface yarn 2 became a non-concave design part, and the uneven design by embossing was not attached | subjected.

  DESCRIPTION OF SYMBOLS 1 ... Fabric with design 2 ... Concave and convex design part 3 ... Non-concave design part

Claims (13)

A polyurethane resin is applied to the surface of the fabric having a low fineness portion and a high fineness portion having a single fineness higher than the low fineness portion on the surface, and after drying, the surface is embossed.
A method for producing a design-attached fabric having a partially uneven design by embossing.   By performing the embossing, a non-concave design portion is formed on the high-definition part without being provided with an uneven design by embossing, while an uneven design by embossing is provided on the low-fineness portion. The manufacturing method of the fabric with a design of Claim 1 which forms a part.   The low-definition portion includes a yarn having a single fineness of 1.5 dtex or less, and the high-fineness portion includes a yarn having a single fineness higher than 1.5 dtex. A method for producing a fabric with a design.   The polyurethane resin is applied so that the penetration thickness of the polyurethane resin in the low-fineness portion is 40 to 400 μm, the filling rate of the polyurethane resin is 10 to 55%, and the filling rate of fibers is 45 to 80%. The manufacturing method of the fabric with a design of any one of Claims 1-3.   The design according to any one of claims 1 to 4, wherein the polyurethane resin is applied so that the porosity in the high-fineness portion is 10% or more and is higher than the porosity in the low-fineness portion. Fabric manufacturing method.   The polyurethane resin is applied so that the polyurethane resin permeates between fibers in at least a surface portion of the fabric so that a fabric surface is formed by the polyurethane resin and the fibers. The manufacturing method of the fabric with a design of description. A polyurethane resin is present on the surface portion, and the fabric has an uneven design portion and a non-recessed design portion on the surface portion,
The concavo-convex design portion is composed of yarn having a single fineness lower than that of the non-concave design portion, and the concavo-convex design by embossing is given to the surface,
The non-concave design part is composed of yarn having a single fineness higher than that of the uneven design part, and the surface is not provided with an uneven design by embossing.
Fabric with design.   The fabric with a design according to claim 7, wherein the uneven design portion is provided with the uneven design by the embossing by adhering adjacent fibers more strongly than the non-concave design portion by the polyurethane resin.   The said uneven | corrugated design part comprises a yarn whose single fineness is 1.5 dtex or less, and the said non-concave design part comprises a yarn whose single fineness is higher than 1.5 dtex. Fabric with design.   The said uneven | corrugated design part is the penetration thickness of the said polyurethane resin of 40-400 micrometers, the filling rate of the said polyurethane resin is 10-55%, and the filling rate of a fiber is 45-80%, Any of Claims 7-9 A fabric with a design according to claim 1.   The fabric with a design according to any one of claims 7 to 10, wherein a porosity in the non-concave design portion is 10% or more and higher than a porosity in the uneven design portion.   The fabric with a design according to any one of claims 7 to 11, wherein the polyurethane resin permeates between fibers in at least a surface portion of the fabric to form a fabric surface with the polyurethane resin and the fibers. The fabric with a design according to any one of claims 7 to 12, wherein the sum of the outer peripheral lengths of the fiber cross-sections in the uneven design portion is 1500 µm or more per unit area of 10000 µm ² .