US20160273130A1 - High-shrinkage acrylic fiber, spun yarn containing the same, and step pile fabric using the spun yarn - Google Patents

High-shrinkage acrylic fiber, spun yarn containing the same, and step pile fabric using the spun yarn Download PDF

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Publication number
US20160273130A1
US20160273130A1 US15/034,568 US201415034568A US2016273130A1 US 20160273130 A1 US20160273130 A1 US 20160273130A1 US 201415034568 A US201415034568 A US 201415034568A US 2016273130 A1 US2016273130 A1 US 2016273130A1
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Prior art keywords
pile
fiber
acrylic fiber
pile fabric
long
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US15/034,568
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Inventor
Tatsuhiko Inagaki
Yukio Onohara
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Mitsubishi Chemical Corp
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Mitsubishi Rayon Co Ltd
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Assigned to MITSUBISHI RAYON CO., LTD. reassignment MITSUBISHI RAYON CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: INAGAKI, TATSUHIKO, ONOHARA, Yukio
Publication of US20160273130A1 publication Critical patent/US20160273130A1/en
Assigned to MITSUBISHI CHEMICAL CORPORATION reassignment MITSUBISHI CHEMICAL CORPORATION MERGER (SEE DOCUMENT FOR DETAILS). Assignors: MITSUBISHI RAYON CO., LTD.
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D1/00—Treatment of filament-forming or like material
    • D01D1/02—Preparation of spinning solutions
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
    • D01D10/06—Washing or drying
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/09—Addition of substances to the spinning solution or to the melt for making electroconductive or anti-static filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D01F1/103—Agents inhibiting growth of microorganisms
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/18—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/026—Tufted products characterised by the tufted pile surface
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05D—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
    • D05D2209/00—Use of special materials
    • D05D2209/10—Particular use of plastics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/10—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/061—Load-responsive characteristics elastic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/062—Load-responsive characteristics stiff, shape retention
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/13—Physical properties anti-allergenic or anti-bacterial
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/16—Physical properties antistatic; conductive

Definitions

  • the present invention relates to acrylic fibers suitable for producing step pile fabrics, spun yarns containing the acrylic fibers, and step pile fabrics produced using the spun yarns.
  • natural furs are generally made of napped fibers with the tip narrower than the base, they have a unique soft texture despite their resilience. In recent years, natural furs are less likely to be used from the standpoint of environmental protection. Thus, development of napped products using synthetic fibers to obtain a texture similar to that of natural furs has been in great demand.
  • acrylic fibers exhibit animal-fur like texture and luster. Thus, they are widely used as pile material for producing animal fur-like napped products.
  • step pile fabric consisting of long-pile and short-pile portions.
  • the long-pile portion is formed to imitate a structure of animal guard hairs and the short-pile portion to imitate a structure of down hairs.
  • step pile fabrics are suitable for producing fabrics with animal fur-like textures.
  • JPH9-78375A (Patent Literature 2), for example, describes fibers for pile material and the like, which are formed with super flat acrylic fiber with a flatness degree of 15 ⁇ 30 and a single-filament fineness of 2 ⁇ 3 denier (2.2 ⁇ 3.3 dtex), shrinkable acrylic fiber with a single-filament fineness of 1 ⁇ 5 denier (1.1 ⁇ 5.6 dtex), and other acrylic fibers.
  • shrinkable fibers having a round cross section are mainly used as the down hair component, and flat fibers are blended in the product.
  • Patent Literature 1 JPH8-260234A
  • Patent Literature 2 JPH9-78375A
  • Patent Literature 3 JPH11-350298A
  • the inventors of the present invention have conducted extensive studies in consideration of the above-mentioned problems, and have found that nap properties are improved when high-shrinkage fibers with modified cross-sectional shapes are used for the down hair component.
  • An acrylic fiber related to the present invention is a high-shrinkage acrylic fiber that has a single-filament fineness of 1 ⁇ 7 dtex, a shrinkage rate of 20 ⁇ 40%, and a post-shrink bulkiness of 0.19 ⁇ 10 1 ⁇ 0.30 ⁇ 10 1 mm 3 /g.
  • the acrylic fiber related to the present invention has a single-filament fineness of 2 ⁇ 7 dtex, an elongation rate of 50 ⁇ 70%, and a bulkiness of 0.19 ⁇ 10 1 ⁇ 0.30 ⁇ 10 1 mm 3 /g.
  • a minimum value of the second moment of area per unit fineness is preferred to be at least 600 ⁇ m 4 in a direction where the second moment of area is smallest, and a maximum value of the second moment of area per unit fineness is at least 2200 ⁇ m 4 in a direction where the second moment of area is greatest.
  • the minimum value of the second moment of area is more preferred to be at least 4000 ⁇ m 4 in a direction where the second moment of area is smallest.
  • acrylic fiber related to the present invention is preferred to satisfy any of requirements (I), (II) and (III) described below:
  • the cross section of a fiber is formed with a circle and rectangle, where the rectangle having a short side shorter than the diameter of the circle penetrates through the circle in such a way that both ends of the rectangle are positioned outside the circle: when the length of the long side of the rectangle is set as “a” and the length of the short side as “b,” “a/b” is 3 ⁇ 25; and when the diameter of the circle is set as “W” and the shorter height of the maximum heights respectively measured from each of both long sides of the rectangle inside the circle is set as “H,” “W” is a/10 ⁇ 4a/5, and “H” is b/2 ⁇ 2b.
  • the cross section of a fiber has a triangular shape: when the length of the longest side of the triangle is set as “C” and the height from the longest side positioned at the base of the triangle is set as “B,” B/C is 0.5 or greater.
  • the cross section of a fiber has a dumbbell shape and the degree of narrowing (X/Y) is 1.1 ⁇ 2.5.
  • X is the maximum length of major diameter between narrowed ends.
  • Y is the length at the narrowest portion.
  • An acrylic fiber related to the present invention is preferred to be made of an acrylonitrile-based polymer containing an acrylonitrile unit at 50 mass % or greater.
  • the spun yarn related to the present invention contains the aforementioned acrylic fiber of the present invention at 20 ⁇ 50 mass %.
  • a step pile fabric related to the present invention consists of a long-pile portion and a short-pile portion.
  • the short-pile portion contains the aforementioned acrylic fiber related to the present invention, and its rate of recovery from compression is 35 ⁇ 90.
  • the content of the aforementioned acrylic fiber contained in the short-pile portion is preferred to be 20 ⁇ 50 mass % of the entire pile portion.
  • the base of pile is preferred to be in the initial state of spun yarn.
  • the short-pile portion of a step pile fabric related to the present invention is preferred to have a pile length of 5 ⁇ 20 mm.
  • the long-pile portion of a step pile fabric related to the present invention is preferred to have a pile length of 6 ⁇ 40 mm.
  • the material for the long-pile portion of a step pile fabric related to the present invention is not limited specifically, and may be made of synthetic fibers or natural fibers selected according to the desired texture to be obtained.
  • fibers it is preferred to contain any one or more fibers selected from among acrylic fibers, polyester fibers and animal fibers.
  • Acrylic fibers are preferred, since crimp is easier to stretch when heat is applied during the finishing process of pile, and a soft texture and an excellent lustrous appearance are obtained.
  • polyester fibers are resilient, they are preferred when a fabric with a rougher texture is desired.
  • animal fibers in long piles, since the texture and appearance are made similar to those of natural material.
  • the content of one or more fibers selected from among acrylic fibers, polyester fibers and animal fibers is preferred to be 50 ⁇ 100 mass % of the entire long-pile portion.
  • the content is preferred to be 50 mass % or greater, more preferably 80 mass % or greater, since it is easier to achieve the characteristics specific to that material.
  • the long-pile portion of a step pile fabric related to the present invention is preferred to have a single-filament fineness of 1 ⁇ 50 dtex.
  • a single-filament fineness of 1 dtex or greater makes it easier to obtain a soft texture, and a single-filament fineness of 50 dtex or less makes it easier to obtain excellent nap properties in the pile fabric.
  • a single-filament fineness of 2 ⁇ 25 dtex is more preferred, even more preferably 3 ⁇ 10 dtex, since spinning stability is excellent and it is easier to stretch a crimp by applying heat during a polishing process.
  • the cross-sectional shape in a fiber axial direction of acrylic fiber or polyester fiber used for the long-pile portion may be selected appropriately from a flat shape, Y shape, UFO shape, dumbbell shape, round shape or the like according to the desired texture.
  • a flat shape, Y shape, UFO shape or dumbbell shape is preferred since such a shape makes it easier to obtain a texture similar to that of animal furs.
  • the difference in length between long-pile and short-pile portions is preferred to be 1 ⁇ 20 mm. If a difference is 1 mm or greater, characteristics specific to the long-pile portion are more likely to be obtained, whereas a difference of 20 mm or less makes it easier to obtain a step pile fabric with excellent nap that recovers well when compressed.
  • the difference in length between long-pile and short-pile portions is more preferred to be 3 ⁇ 15 mm, even more preferably 5 ⁇ 10 mm.
  • step pile fabrics with excellent nap that recovers well when compressed are obtained, and acrylic fibers suitable for producing such step pile fabrics are also obtained.
  • FIG. 1 is a cross-sectional view perpendicular to the fiber axis of high-shrinkage acrylic fiber (I) related to the present invention
  • FIG. 2 is a cross-sectional view perpendicular to the fiber axis of high-shrinkage acrylic fiber (II) related to the present invention
  • FIG. 3 is a cross-sectional view perpendicular to the fiber axis of high-shrinkage acrylic fiber (III) related to the present invention.
  • FIG. 4 is a perspective view seen from diagonally above when an acrylic fiber bundle related to the present invention is measured by using a bulkiness measuring instrument.
  • An acrylonitrile-based polymer used in the embodiments of the present invention is made of acrylonitrile and an unsaturated monomer polymerizable with the acrylonitrile.
  • unsaturated monomers are acrylic acid, methacrylic acid and their alkyl esters, vinyl acetate, acrylamide, vinyl chloride and vinylidene chloride.
  • ionic unsaturated monomers may also be used, for example, sodium vinylbenzensulfonate, sodium methallyl sulfonate, sodium allyl sulfonate, sodium acrylamide methylpropane sulfonate, sodium para-sulfophenyl methallyl ether and the like.
  • the amount of an acrylonitrile unit contained in a polymer is preferred to be 50 mass % or greater, more preferably 80 mass % or greater, even more preferably 90 mass % or greater, while its upper limit is preferred to be 99 mass % or less.
  • the resultant fiber is strong enough to be used.
  • the content of the acrylonitrile unit in the polymer is 99 mass % or less in the polymer, excellent results are achieved when the fiber is dyed.
  • the acrylonitrile-based polymer of an acrylic fiber related to the present invention may be made of one type of a polymer, or may be mixed with two or more polymers containing different amounts of acrylonitrile.
  • Suspension polymerization, solution polymerization or the like may be selected as a method for polymerizing the acrylic polymer, but any other method may also be employed.
  • the molecular weight of the acrylic polymer is not limited specifically as long as it is within a range generally used for producing acrylic fibers. However, when the acrylic polymer is made into a 0.5 wt % dimethylformamide solution, the reduced viscosity at 25° C. is preferred to be in a range of 1.5 ⁇ 3.0 in view of spinning stability and fiber strength.
  • a spinning dope is prepared by dissolving an acrylic polymer in a solvent to have a concentration of 15 ⁇ 28 mass %.
  • concentration is at least 15 mass %, the cross-sectional shape of the fiber is not so different from the shape of the discharge port of a spinning nozzle when it is coagulated, and a desired cross-sectional shape is easier to obtain.
  • a concentration of no greater than 28 mass % is preferred, since the chronological stability of the spinning dope is excellent, and spun results are most likely to be stable.
  • the solvent in addition to organic solvents such as dimethylformamide, dimethylacetamide, and dimethylsulfoxide, nitric acid, a Rhodanate solution, zinc chloride solution or the like may also be used.
  • organic solvents such as dimethylformamide, dimethylacetamide, and dimethylsulfoxide, nitric acid, a Rhodanate solution, zinc chloride solution or the like may also be used.
  • organic solvents such as dimethylformamide, dimethylacetamide, and dimethylsulfoxide, nitric acid, a Rhodanate solution, zinc chloride solution or the like may also be used.
  • organic solvents such as dimethylformamide, dimethylacetamide, and dimethylsulfoxide, nitric acid, a Rhodanate solution, zinc chloride solution or the like.
  • dimethylacetamide is more preferred.
  • drafting which is defined by the ratio of the take-off speed of the coagulated fiber relative to the discharge linear velocity of the spinning solution, is set to be 0.7 ⁇ 2.0, it is easier to obtain an acrylic fiber with a modified cross-sectional shape that is substantially similar to the shape of a discharge port of a spinning nozzle.
  • a drafting of 0.7 or greater is preferred, since the cross-sectional shape of the fiber is not so different from the shape of the discharge port of a spinning nozzle during coagulation, and a desired cross-sectional shape is more likely to be obtained.
  • the obtained coagulated fiber is stretched, washed and dried by conventional methods and conditions. Then, after a relaxation process, the fiber is stretched in a steam-stretching process to be 1.10 ⁇ 2.00 times longer so as to obtain a thermally shrinkable acrylic fiber with a shrinkage rate of 20 ⁇ 40% according to the present invention.
  • the fiber is cut into a predetermined length according to usage purposes.
  • the raw stock is processed into a pile fabric through a conventionally known pile processing method.
  • the acrylic fiber of the present invention is shrinkable when wet heat or dry heat is applied thereon.
  • One of the main purposes of an acrylic fiber related to the present invention is to be contained in the short-pile portion of a step-pile fabric.
  • the single-filament fineness of the acrylic fiber before it shrinks is preferred to be 1 ⁇ 7 dtex.
  • a single-filament fineness of at least 1 dtex makes it easier to obtain excellent nap properties when formed into a step pile fabric, while a single-filament fineness of no greater than 7 dtex makes it easier to obtain a soft texture when formed into a step pile fabric.
  • the single-filament fineness is more preferred to be 1 ⁇ 5 dtex and even more preferably 2 ⁇ 4 dtex.
  • the shrinkage rate of an acrylic fiber related to the present invention it is sufficient if the shrinkage rate when exposed to wet heat (processed 3 minutes in boiling water) or when exposed to dry heat (processed 10 minutes at 130° C.) is 20 ⁇ 40%.
  • a shrinkage rate of at least 20% means sufficient shrinkable properties, while bulkiness and design effects of pile portions are achieved in step pile fabrics. Also, if the shrinkage rate is no greater than 40%, the texture of a step pile fabric maintains softness, and excellent product quality is thus secured.
  • the shrinkage rate is more preferred to be 25 ⁇ 35%, even more preferably 27 ⁇ 33%.
  • Post-shrink bulkiness of an acrylic fiber related to the present invention is 0.19 ⁇ 10 1 ⁇ 0.30 ⁇ 10 1 mm 3 /g.
  • Bulkiness of at least 0.19 ⁇ 10 1 mm 3 /g makes it easier to form a step pile fabric with excellent nap and volume. If the bulkiness is no greater than 0.30 ⁇ 10 1 mm 3 /g, the texture of a step pile fabric maintains softness, and excellent product quality is thus secured. From those viewpoints, the bulkiness is more preferred to be 0.21 ⁇ 10 1 ⁇ 0.25 ⁇ 10 1 mm 3 /g.
  • an acrylic fiber related to the present invention is to be contained in the short-pile portion of a step-pile fabric.
  • the acrylic fiber is preferred to have a post-shrink single-filament fineness of 2 ⁇ 7 dtex.
  • a single-filament fineness of at least 2 dtex is preferred, since the rate of recovery from compression is excellent when the fiber is used in the short-pile portion of a step pile fabric, while a single-filament fineness of no greater than 7 dtex is preferred because that makes it easier to maintain a soft texture.
  • the single-filament fineness is more preferred to be 2 ⁇ 5 dtex and even more preferably 2 ⁇ 4 dtex.
  • the elongation rate of an acrylic fiber related to the present invention is 50 ⁇ 70%.
  • An elongation rate of at least 50% is preferred since it is easier to form a step pile fabric with excellent nap properties.
  • an elongation rate of no greater than 70% is preferred, since the density of the step pile fabric will not increase too much and stiff texture is prevented.
  • the elongation rate is more preferred to be 52 ⁇ 65%, even more preferably 56 ⁇ 63%.
  • the second moment of area means the degree of difficulty to deform an object in question relative to a bending moment.
  • a higher value of the second moment of area means that the object is less likely to bend, while a lower value means the object is more likely to bend.
  • the value of the second moment of area varies depending on the direction of bending.
  • the minimum value of the second moment of area per unit fineness is preferred to be 600 ⁇ m 4 or greater in a direction where the second moment of area is smallest; and the maximum value of the second moment of area per unit fineness is preferred to be 2200 ⁇ m 4 or greater in a direction where the second moment of area is greatest.
  • the minimum value of the second moment of area per unit fineness is at least 600 ⁇ m 4 in a direction where the second moment of area is smallest, and when the fiber is used in the short-pile portion of a step pile fabric, the nap is less likely to be flattened under external force; even if the pile is flattened, the nap is more likely to recover from compression. From those viewpoints, the minimum value is more preferred to be 1000 ⁇ m 4 or greater, even more preferably 4000 ⁇ m 4 or greater.
  • the maximum value of the second moment of area per unit fineness is at least 2200 ⁇ m 4 in a direction where the second moment of area is greatest, and when the fiber is used in the short-pile portion of a step pile fabric, the nap is less likely to be flattened under external force; even if the pile is flattened, the nap is more likely to recover from compression. From those viewpoints, the maximum value is more preferred to be 6000 ⁇ m 4 or greater, even more preferably 10000 ⁇ m 4 or greater.
  • the minimum value of the second moment of area per unit fineness in a direction where the second moment of area is smallest is preferred to be at least 4000 ⁇ m 4 , since the nap is less likely to be flattened under external force when the fiber is used in the short-pile portion of a step pile fabric.
  • the cross-sectional shape of an acrylic fiber related to the present invention is not limited specifically. The following are examples.
  • Requirement (I) is as follows.
  • the fiber cross section is formed with a circle and rectangle, where the rectangle having a short side shorter than the diameter of the circle penetrates through the circle in such a way that both ends of the rectangle are positioned outside the circle.
  • a/b is 3 ⁇ 25;
  • the diameter of the circle is set as “W” and the smaller value of the maximum heights respectively measured from each of the long sides of the rectangle positioned inside the circle is set as “H,” “W” needs to be a/10 ⁇ 4a/5, and “H” needs to be b/2 ⁇ 2b.
  • a fiber cross section indicates the cross section of a fiber perpendicular to the longitudinal direction of the fiber.
  • Requirement (II) is as follows.
  • a fiber cross section has a triangular shape; in such a triangle, when the length of the longest side among three sides of the triangle is set as “C” and the height from the longest side positioned at the base is set as “B”, then B/C needs to be 0.5 or greater. If B/C is less than 0.5, the triangle becomes a narrow flat shape, and desired effects are not achieved since the resilience properties of the fiber cross section are reduced. In addition, the maximum value of B/C is 0.87 when it is an equilateral triangle. Moreover, it is an option for the cross section to be an approximate triangle where the angles are slightly rounded.
  • Requirement (III) is as follows.
  • the single fiber cross section is shaped like a dumbbell, where the maximum length of major diameter between narrowed ends is set as “X” and the length at the narrowest portion is set as “Y,” the degree of narrowing (X/Y) needs to be 1.1 ⁇ 2.5.
  • the degree of narrowing is at least 1.1, the fiber cross section is closer to a regular flat cross section, and desired resilience and nap properties are achieved. If the degree of narrowing is 2.5 or less, a decrease in spinning stability and a reduction in fiber strength are suppressed.
  • the acrylic fiber related to the present invention forms the short-pile portion of a step pile fabric.
  • the acrylic fiber is blended with other fibers at a predetermined rate and is formed into a yarn by a conventional method.
  • the rate of blending the acrylic fiber related to the present invention is preferred to be 20 ⁇ 50 mass %.
  • the blending rate is 20 mass % or greater, the volume of a step pile fabric is not lowered, and when the rate is 50 mass % or less, the soft texture of a step pile fabric is maintained.
  • fibers to be blended are not limited to any particular type.
  • a step pile fabric may be produced by employing any known methods such as a method for producing a pile fabric from spun yarn and a method for producing a pile fabric by high-pile knitting.
  • the high-shrinkage acrylic fiber related to the present invention is used, it is preferred to be formed into spun yarn, from which pile is produced, because such a method makes it easier to form different lengths in the short-pile and long-pile portions respectively.
  • the short-pile portion contains the acrylic fiber of the present invention, and the later-described rate of recovery from compression is set to be 35 ⁇ 90.
  • a step pile fabric related to the present invention When a step pile fabric related to the present invention is set to have a rate of recovery from compression at 35 or greater, even if the nap of the fabric is flattened when compressed by external force, the nap is more likely to recover.
  • the maximum value of the rate of recovery from compression is 90.
  • the rate of recovery from compression is more preferred to be at least 38, even more preferably at least 43.
  • the acrylic fiber described above is preferred to be contained at 20 ⁇ 50 mass % of the entire pile portion.
  • the content of the acrylic fiber related to the present invention is at least 20 mass % of the entire pile portion, the nap of the long-pile portion is excellent, and desired resilience and nap properties are achieved. If the content is no greater than 50 mass %, the blending ratio relative to the long-pile portion is not too low, thus excellent texture is achieved in the long-pile portion. Accordingly, a texture similar to that of natural fur is obtained.
  • the content is more preferred to be 30 ⁇ 45 mass %. Considering the above viewpoints, 35 ⁇ 40 mass % is preferred.
  • the base of pile is preferred to maintain the initial state of spun yarn. If the base of pile is in the initial state of spun yarn, the fiber bundle is less likely to collapse at the base. Thus, a step pile fabric with excellent nap properties is formed.
  • the length that maintains the initial state of spun yarn is preferred to be 1 ⁇ 5 mm, considering nap properties.
  • the length of the short-pile portion is preferred to be 5 ⁇ 20 mm.
  • a short-pile portion having a length of at least 5 mm maintains excellent nap properties, and a short-pile portion having a length of no greater than 20 mm provides soft texture for the step pile fabric.
  • the length of a short-pile portion is preferred to be 5 ⁇ 10 mm, considering the above features.
  • the difference in lengths of the short-pile and long-pile portions is preferred to be 1 ⁇ 20 mm. Such a range is preferred because the step pile fabric can achieve both the nap properties and texture similar to those of natural furs.
  • the pile length of a long-pile portion is especially preferred to be 6 ⁇ 40 mm in a step pile fabric related to the present invention. If the pile length of a long-pile portion is no greater than 40 mm, the firmness and resilience of acrylic fiber prevent fiber tips from converging.
  • the measurement process above is repeated three times, and the average value is employed as the shrinkage rate.
  • acrylic fiber bundles 15 formed of n acrylic fibers as one bundle are arranged on the upper surface of third board member 13 .
  • “n” is set at 500 ⁇ 800.
  • the fiber portions protruding from jig main body 10 are cut off so as to line up edges of fiber bundles on both ends.
  • the measurement is conducted 10 times, and the average value is employed as the bulkiness (mm 3 /g).
  • the second moment of area of each cross-sectional shape is measured, and directions of X- and Y-axes of each cross-sectional shape are changed appropriately to obtain the minimum and maximum values of each second moment of area.
  • values obtained as minimum and maximum values of the second moment of area are divided by single-filament fineness, and the calculated values are set to be the minimum and maximum values of the second moment of area per unit fineness.
  • the rate of recovery from compression is evaluated as follows.
  • a step pile fabric is cut into a 3 cmx3 cm piece, and the piece with a load of 141 g/cm 2 applied thereon is left standing for three days in a dryer with a temperature set at 35° C.
  • angle “A” of a nap is measured immediately after the load is removed.
  • the same piece is left standing for one day in room temperature (25° C., relative humidity of 65%), and angle “B” of the same nap is measured.
  • Angles “A” and “B” are those measured between the horizontal surface of a fabric piece and the direction of nap (acute angles).
  • the rate of recovery from compression observed in the nap of a step pile fabric is calculated by (B-A).
  • the rate of recovery from compression means the amount of change of nap angles observed in a day after a load is removed. The measurement is conducted 10 times, and the average value is employed as the rate at which the step pile fabric recovers from compression.
  • a copolymer consisting of 90 mass % of acrylonitrile and 10 mass % of vinyl acetate was obtained through solution suspension polymerization.
  • a 0.5 mass % dimethylformamide solution of the polymer had a reduced viscosity of 2.0 at 25° C.
  • the polymer was dissolved in dimethylacetamide to prepare a spinning dope with a polymer concentration of 24 mass %. From the discharge port of a spinning nozzle with a cross-sectional shape specified in Table 1, the spinning dope was discharged into a dimethylacetamide solution with a solvent concentration of 40% to obtain coagulated fiber. The coagulated fiber was further stretched in hot water to be five times as long, was washed, and was dried with a drying roll.
  • the fiber was subjected to a heat relaxation process in a compressed steam ambient. After that, the fiber was stretched in a steam stretching process to be twice as long, and was crimped mechanically. Accordingly, an acrylic fiber was obtained.
  • the shrinkage rate of the acrylic fiber is shown in Table 1.
  • an acrylic fiber bundle was cut into an approximately 2 m-long sample.
  • the sample was placed into a container, and the acrylic fiber was set to shrink for 3 minutes in the container under a flow of 100° C. steam.
  • the shape and physical properties of post-shrink acrylic fiber are shown in Tables 1 and 2.
  • Tables 1 and 2 show the post-shrink shape and various physical properties of acrylic fibers except for shrinkage rates.
  • a pre-shrink acrylic fiber was cut into various lengths ranging from 76 ⁇ 127 mm.
  • Blended fibers were prepared by using 40 mass % of the acrylic fiber and 60 mass % of acrylic fiber with a flat fiber cross section (flatness degree of 7) (product number H155 BRE3.3 TVCL, single-filament fineness of 3.3 dtex, variable cut fiber length of 76 ⁇ 127 mm, shrinkage rate of 0%, made by Mitsubishi Rayon).
  • the blended fibers were subjected to regular worsted spinning, and a spun yarn with a yarn count of 2/28 Nm was obtained.
  • the spun yarn was subjected to a process for creating bulkiness and to a skein dyeing. After the yarn was knitted and cut, known pile procedures such as brushing, polishing and shearing were conducted to obtain a step pile fabric. Evaluation results of the step pile fabric are shown in Table 3.
  • Acrylic fibers were each prepared the same as in Example 1 except that the cross-sectional shape of the discharge port of a spinning nozzle was changed to obtain a post-shrink cross-sectional shape of acrylic fiber as shown in Table 1. Accordingly, acrylic fibers as shown in Tables 1 and 2 were obtained.
  • Step pile fabrics were each formed the same as in Example 1 except that fibers in the short-pile portion were respectively changed to the fibers obtained above. Evaluation results of step pile fabrics are shown in Table 3.
  • Acrylic fiber was prepared the same as in Example 1 except that the cross-sectional shape of the discharge port of a spinning nozzle was changed and no steam stretching was conducted. Accordingly, acrylic fiber as shown in Tables 1 and 2 was obtained. The fiber was cut into 38 mm lengths.
  • a step pile fabric was obtained as follows: a sliver was formed by blending 40 mass % of the above acrylic fiber with an acrylic fiber having a flat fiber cross section (flatness degree of 7) (product number: H155 BRE3.3 TM, single-filament fineness of 3.3 dtex, fiber length of 51 mm, shrinkage rate of 0%, made by Mitsubishi Rayon); then, a pile fabric was formed by sliver knitting, and pile procedures such as brushing, polishing and shearing were conducted on the pile fabric. Accordingly, a step pile fabric was obtained by using the acrylic fiber in Table 1 in the short-pile portion and acrylic fiber (product number: H155 BRE3.3 T51) in the long-pile portion. Evaluation results of the step pile fabric are shown in Table 3.
  • Acrylic fibers as shown in Tables 1 and 2 were each prepared the same as in Comparative Example 3 except that the cross-sectional shape of the discharge port of a spinning nozzle was changed.
  • a step pile fabric was formed the same as in Comparative Example 3 except that the acrylic fiber obtained in Comparative Example 3 was replaced with those obtained in Comparative Examples 4, 5. Evaluation results of the step pile fabrics are shown in Table 3.
  • Example 1 Comp. — — — — — — — — — — — — 7 flat type
  • Example 2 Comp. — — — — — — 7 flat type
  • Example 3 Comp. — — — — — — — — — — — round type
  • Example 5 (requirement I)

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Manufacturing & Machinery (AREA)
  • Woven Fabrics (AREA)
  • Knitting Of Fabric (AREA)
  • Artificial Filaments (AREA)
  • Nonwoven Fabrics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
US15/034,568 2013-11-08 2014-11-06 High-shrinkage acrylic fiber, spun yarn containing the same, and step pile fabric using the spun yarn Abandoned US20160273130A1 (en)

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PCT/JP2014/079493 WO2015068774A1 (ja) 2013-11-08 2014-11-06 高収縮性アクリル繊維と同繊維を含む紡績糸と同紡績糸を用いた段差パイル布帛

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US20180245244A1 (en) * 2015-10-30 2018-08-30 Kaneka Corporation Pile fabric

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WO2018074544A1 (ja) * 2016-10-19 2018-04-26 三菱ケミカル株式会社 繊維及び詰め綿
CN107571580A (zh) * 2017-07-28 2018-01-12 阳信瑞鑫集团有限公司 一种加银丝割绒块毯制作工艺
WO2019187451A1 (ja) * 2018-03-27 2019-10-03 株式会社カネカ パイル布帛
EP3822398A4 (en) * 2018-07-11 2022-03-16 Kaneka Corporation POLYESTER BASED FIBER AND UPHOLSTERY CLOTH WITH USE THEREOF AND METHODS OF MAKING THESE PRODUCTS RELATIVELY
WO2020045183A1 (ja) * 2018-08-30 2020-03-05 日本エクスラン工業株式会社 アクリロニトリル系繊維、該繊維を含有するパイル布帛及び該布帛を含有する繊維製品
EP4083285A4 (en) * 2019-12-25 2023-10-11 Kaneka Corporation Pile fabric and process for its production

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US3739054A (en) * 1971-04-05 1973-06-12 Bayer Ag Process for the production of high shrinkage threads yarns and fibersfrom acrylonitrile polymers
US3828014A (en) * 1967-09-07 1974-08-06 Bayer Ag High shrinkage threads,yarn and fibers from acrylonitrile polymers
US3976737A (en) * 1972-09-14 1976-08-24 Japan Exlan Company Limited Process for producing high shrinking acrylic fiber
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US20050019562A1 (en) * 2001-12-28 2005-01-27 Ryo Ochi Highly shrinkable acrylic fiber, pile compositions containing the same and napped fabrics made by using the compositions
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JP3565630B2 (ja) 1995-09-11 2004-09-15 三菱レイヨン株式会社 パイル用原綿
JPH09157985A (ja) * 1995-12-13 1997-06-17 Toyobo Co Ltd カーペット用ポリエステル繊維糸の製造方法
JPH10237721A (ja) * 1997-02-24 1998-09-08 Mitsubishi Rayon Co Ltd 高収縮性アクリル繊維及びパイル用原綿
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US3111366A (en) * 1961-09-01 1963-11-19 Japan Exlan Co Ltd Method for producing high shrinking acrylonitrile polymer fibres
US3828014A (en) * 1967-09-07 1974-08-06 Bayer Ag High shrinkage threads,yarn and fibers from acrylonitrile polymers
US3739054A (en) * 1971-04-05 1973-06-12 Bayer Ag Process for the production of high shrinkage threads yarns and fibersfrom acrylonitrile polymers
US3976737A (en) * 1972-09-14 1976-08-24 Japan Exlan Company Limited Process for producing high shrinking acrylic fiber
US4067948A (en) * 1975-07-18 1978-01-10 Bayer Aktiengesellschaft Process for the production of high-shrinkage wet-spun acrylic fibres or filaments
US20050019562A1 (en) * 2001-12-28 2005-01-27 Ryo Ochi Highly shrinkable acrylic fiber, pile compositions containing the same and napped fabrics made by using the compositions
JP2012036513A (ja) * 2010-08-04 2012-02-23 Mitsubishi Rayon Co Ltd パイル布帛

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CN105705687B (zh) 2018-01-12
JPWO2015068774A1 (ja) 2017-03-09
KR101777180B1 (ko) 2017-09-11
TW201527613A (zh) 2015-07-16
KR20160062148A (ko) 2016-06-01
TWI609107B (zh) 2017-12-21
WO2015068774A1 (ja) 2015-05-14
JP5817942B2 (ja) 2015-11-18

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