WO2024128202A1

WO2024128202A1 - Polyethylene terephthalate-based fabric hook-and-loop fastener and method for manufacturing same

Info

Publication number: WO2024128202A1
Application number: PCT/JP2023/044305
Authority: WO
Inventors: 佳克藤澤; 卓相良
Original assignee: クラレファスニング株式会社
Priority date: 2022-12-15
Filing date: 2023-12-11
Publication date: 2024-06-20

Abstract

Provided is a hook-and-loop fastener woven from polyethylene terephthalate-based threads. A resin layer (6) composed of a polyethylene terephthalate-based resin having a melting point of 160-210 °C copolymerized with isophthalic acid is directly overlaid on a second face of a base fabric (5) which is a woven fabric obtained by using threads composed of a polyethylene terephthalate-based resin as a warp (2), a weft (3), and an engaging element thread (3).

Description

Polyethylene terephthalate-based woven hook-and-loop fastener and its manufacturing method

Related Applications

This application claims priority to Patent Application No. 2022-200317, filed in Japan on December 15, 2022, the entire contents of which are incorporated herein by reference as a part of this application.

The present invention relates to a hook-and-loop fastener woven from polyethylene terephthalate (hereinafter sometimes abbreviated as PET)-based yarn.

Conventionally, as a hook-and-loop fastener having a woven base fabric, a combination of a so-called woven hook fastener, which has a large number of hook-shaped engaging elements made of monofilament yarn on the surface of the woven base fabric, and a so-called woven loop fastener, which has a large number of loop-shaped engaging elements made of multifilament yarn on the surface of the woven base fabric that can engage with the hook-shaped engaging elements, has been widely used in fields such as clothing and daily necessities, because there is little damage to the engaging elements and little decrease in engaging force even when repeatedly engaging and peeling.

　In addition, so-called hook-and-loop coexisting woven hook-and-loop fasteners, in which both the above-mentioned hook-shaped engaging elements and loop-shaped engaging elements are present in large numbers on the same surface of a woven base fabric, are also widely used because they can provide the functions of both hook and loop hook-and-loop fasteners in a single type of hook-and-loop fastener, eliminating the need to use both hook and loop hook-and-loop fasteners as with conventional hook-and-loop fasteners.

Such woven hook-and-loop fasteners are woven from warp threads, weft threads, and threads for the engaging elements. Nylon-based threads are usually used for these warp threads, weft threads, and threads for the engaging elements because of their excellent flexibility, and the resulting hook-and-loop fastener has a soft, gentle feel. In the case of woven hook-and-loop fasteners, the engaging elements are pulled from the surface of the base fabric every time the fastening and unfastening are repeated. In order to prevent the engaging elements from being pulled out of the base fabric by such pulling, a method called a back coat is used in which a solution or dispersion of polyurethane or polyacrylic resin is applied and dried on the back side of the base fabric (i.e., the side opposite to the front side on which the engaging elements are present), and the threads for the engaging elements are adhered and fixed to the base fabric. For example, Patent Document 1 describes the use of nylon-based threads as the warp threads, weft threads, and threads for the engaging elements, and the application and drying of a polyurethane-based back coat resin liquid on the back side of the resulting woven fabric for the hook-and-loop fastener.

In recent years, PET-based fibers have come to be widely and commonly used in the textile product field, such as clothing, footwear, gloves, and daily necessities, and a so-called recycling system has become widespread in which textile products made from these PET-based fibers are collected, remelted, spun into fibers, and reused as textile products. Also, a system is becoming more widespread in which used PET bottles are collected, melted, spun into fibers, and reused as textile products.

As for the hook-and-loop fasteners used as fasteners for these PET-based textile products, in order to be recycled, they must be submitted to the recycling system together with the textile product without being removed from the textile product. However, in the case of conventional woven hook-and-loop fasteners, the thread used is nylon-based, and the back coat layer applied to the reverse side is made of polyurethane or polyacrylic resin, so they cannot be used in the recycling system for PET-based textile products.

As an alternative to nylon-based woven hook-and-loop fasteners that cannot be recycled in this way, Patent Document 2 describes a PET-based woven hook-and-loop fastener that uses PET-based yarns for both the warp threads and the threads for the engaging elements, and further uses heat-fusible PET-based yarns for the weft threads, and fuses the heat-fusible PET-based yarns used as the weft threads to fix the threads for the engaging elements to the base fabric, thereby imparting pull-out resistance to the engaging elements.

Indeed, the PET-based woven hook-and-loop fastener described in Patent Document 2 is made up of PET-based threads, and further uses PET-based heat-fusible threads for the weft threads instead of a polyurethane or polyacrylic back coat resin applied to the back side of the base fabric. This eliminates the need for a back coat resin, and since there are no substances that would prevent the fastener from being sent to the recycling system, the woven hook-and-loop fastener attached to the PET-based textile product can be sent to the recycling system in its attached state without being peeled off.

However, in the case of the technology described in Patent Document 2, in which a heat-fusible yarn is used for the weft and this heat-fusible yarn is melted to make the engaging elements resistant to pulling out, the heat-fusible yarn present in the middle part of the base fabric melts, and the entire base fabric from the front side to the back side is fixed by the heat-fusible yarn, which makes the entire base fabric hard and the feel of the hook-and-loop fastener surface hard, which is not necessarily suitable for applications such as clothing, gloves, and footwear that require a soft feel. In addition, PET-based yarns are stiffer than nylon-based yarns, which makes the feel of the hook-and-loop fastener surface even harder.

Patent Document 3 also describes a hook-and-loop fastener in which a synthetic resin sheet material is welded and integrated to the back surface of a woven or knitted hook-and-loop fastener, and that the synthetic resin that forms the hook-and-loop fastener can be polyester resin or polypropylene resin in addition to nylon-based resin, that the synthetic fibers that form the hook-and-loop fastener and the sheet material welded and integrated to the back surface are preferably formed from the same synthetic resin because they can be firmly integrated, that the melting point of the synthetic fibers that form the hook-and-loop fastener can be higher, equal to, or lower than the melting point of the sheet material welded to the back surface, that the hook-and-loop fastener obtained in this way has resin from the sheet material flowing between the weave of the base fabric and also flowing to the front surface, and that the base fabric and the sheet material do not easily peel off during use, making the hook-and-loop fastener strong and rigid, and that the resulting hook-and-loop fastener is suitable as an industrial material for use in tunnel construction and the like, taking advantage of its strength and rigidity.

However, as described in the examples of the hook-and-loop fastener described in Patent Document 3, when the sheet material is welded to the back surface of the hook-and-loop fastener, the molten resin of the sheet material flows between the weave of the hook-and-loop fastener, penetrates the weave, and flows out to the surface, so the resulting hook-and-loop fastener has rigidity as described above, in other words, the entire base fabric of the hook-and-loop fastener is fixed by the resin, giving it a strong resin sheet feel, and the flexibility of the woven hook-and-loop fastener and the soft feel of the hook-and-loop fastener surface are lost.

Patent Document 4 describes a hook-and-loop fastener in which a low-melting polyester-based hot melt resin layer is integrated with the back surface of the PET-based hook-and-loop fastener described in Patent Document 2, enabling heat-sealing with an iron or the like as a means of attaching the hook-and-loop fastener to an object. However, the hook-and-loop fastener described in Patent Document 4 uses heat-sealable threads as the weft threads, just like the technology in Patent Document 2, and therefore the entire base fabric from the front side to the back side is still fixed by heat-sealable weft threads. Furthermore, since the warp threads and threads for the engaging elements used are PET-based threads, it does not solve the problem of the surface of the hook-and-loop fastener becoming hard to the touch, just like the technology in Patent Document 1.

JP 2003-299508 A International Publication No. 2005/122817 JP 2000-17311 A International Publication No. 2020/149361

The first object of the present invention is to provide a woven hook-and-loop fastener which is woven from PET-based yarns and which, although made from a rigid PET resin, can prevent the entire base fabric from becoming hard by combining it with a specific PET-based binder resin, has excellent engaging force, and can be recycled into a recycling system after use, and in particular can be recycled into a recycling system while still attached to a PET-based textile product.
The second object of the present invention is to provide a woven hook-and-loop fastener which, in addition to the first object, has a soft and gentle feel on the surface of the engaging element side of the woven hook-and-loop fastener, which allows recycled yarn to be used as the yarn constituting the hook-and-loop fastener, and which, when dyed with disperse dyes, results in almost no difference in dyeing between the base fabric part of the hook-and-loop fastener and the resin layer integrated on the back side, giving no impression that something of a different color is integrated on the back side, and which can be simultaneously dyed in approximately the same color as the textile product when the hook-and-loop fastener is attached to the textile product.

That is, the present invention can be configured in the following manner.
[Aspect 1]
A woven fabric surface fastener having a base fabric woven with warp yarns, weft yarns and threads for engaging elements, a first surface of the base fabric being the front side and a second surface being the back side, the threads for engaging elements being woven into the base fabric parallel to the warp yarns, and a number of hook-shaped and/or loop-shaped engaging elements formed from the threads for engaging elements and rising from the first surface of the base fabric are present on the first surface of the base fabric, and the warp yarns, weft yarns and threads for engaging elements are all constituted by threads made of a polyethylene terephthalate-based resin, comprising the following configurations 1) and 2):
1) A binder layer made of a polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C (preferably 170 to 205°C) is provided on the second surface of the base fabric, and the engaging element thread is directly bonded and fixed by the resin of the binder layer;
and 2) the first surface of the base is free of the resin of the binder layer;
This is a polyethylene terephthalate-based woven hook-and-loop fastener that satisfies both of these requirements.
[Aspect 2]
A woven fabric surface fastener having a base fabric woven with warp yarns, weft yarns and threads for engaging elements, a first surface of the base fabric being the front side and a second surface being the back side, the threads for engaging elements being woven into the base fabric parallel to the warp yarns, and a number of hook-shaped and/or loop-shaped engaging elements formed from the threads for engaging elements and rising from the first surface of the base fabric are present on the first surface of the base fabric, and the warp yarns, weft yarns and threads for engaging elements are all constituted by threads made of a polyethylene terephthalate-based resin, comprising the following configurations 1) and 2):
1) a binder layer made of a polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C (preferably 170 to 205°C) is provided on the second surface of the base fabric, a part of the resin of the binder layer penetrates into the inside of the base fabric, and the engaging element yarn is bonded almost entirely by the resin constituting the binder layer at a portion on the second surface of the base fabric where the engaging element yarn is embedded under the weft yarn; and 2) the warp yarn and the engaging element yarn are not bonded to the weft yarn at a portion on the first surface of the base fabric where the warp yarn and the engaging element yarn cross the weft yarn.
This is a polyethylene terephthalate-based woven hook-and-loop fastener that satisfies both of these requirements.
[Aspect 3]
3. A polyethylene terephthalate-based woven surface fastener according to

claim

1 or 2, wherein at least one of the warp threads and the weft threads is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 257°C.
[Aspect 4]
A polyethylene terephthalate-based woven surface fastener according to any one of aspects 1 to 3, wherein the thread for the engaging element is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 265°C (preferably 250 to 257°C).
[Aspect 5]
The polyethylene terephthalate-based woven surface fastener according to any one of aspects 1 to 4, wherein the warp yarns, weft yarns and threads for engaging elements are all made of a copolymerized polyethylene terephthalate resin containing, as copolymerization components, 1.0 to 2.0 mol % of isophthalic acid based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % of diethylene glycol based on the total amount of diols.
[Aspect 6]
A polyethylene terephthalate-based woven fabric hook-and-loop fastener according to any one of Aspects 1 to 5, wherein the binder layer bonded to the second surface of the base fabric has a large number of holes penetrating the layer in the thickness direction.
[Aspect 7]
A textile product with a polyethylene terephthalate-based woven fabric hook-and-loop fastener, in which the polyethylene terephthalate-based woven fabric hook-and-loop fastener according to any one of aspects 3 to 5 is attached to a textile product made of a polyethylene terephthalate-based resin and dyed the same color as the textile product with the same disperse dye.
[Aspect 8]
A method for producing a woven fabric surface fastener using a woven fabric as a base fabric, the woven fabric being composed of warp yarns made of polyethylene terephthalate resin copolymerized with isophthalic acid and weft yarns and yarns for engaging elements made of polyethylene terephthalate resin, a first surface of the base fabric being the front side and a second surface being the back side, the yarns for engaging elements being woven into the base fabric parallel to the warp yarns, the first surface of the base fabric having a number of hook-shaped and/or loop-shaped engaging elements formed from the yarns for engaging elements and rising from the surface of the base fabric, and the second surface of the base fabric having a binder layer made of polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C (preferably 170 to 205°C), characterized in that the following steps A, B and C are carried out in this order.
[Step A] A step of weaving a loop fabric by weaving threads for engaging elements parallel to the warp threads and simultaneously causing the threads for engaging elements to rise in regular loops from the first surface of the base fabric at the locations where the threads cross the weft threads,
[Step B] A step of attaching the resin for the binder layer to the second surface of the base fabric and adhering and fixing the yarn for the engaging element with the resin of the binder layer;
[Step C] When the loop is made of monofilament yarn, a step of heating the first surface side of the loop fabric to fix the loop shape, followed by cooling, and cutting one leg of the loop to make the loop into a hook-shaped engaging element.
Aspect 9
The above-mentioned [Step B] is a process for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to the embodiment 8, in which the resin for the binder layer is attached in a molten state as a film-like material to the second surface of the loop fabric, directly pressed against the second surface of the loop fabric and densified to allow a portion of the film-like material to penetrate into the interior of the second surface of the base fabric, and then the molten resin is cooled and solidified to adhere to the yarn for the engaging elements.
[Aspect 10]
A method for producing a polyethylene terephthalate-based woven fabric surface fastener according to

aspect

8 or 9, wherein the film-like material made of the resin for the binder layer is obtained by heating and melting a fiber sheet.
[Aspect 11]
The method for producing a polyethylene terephthalate-based woven surface fastener according to any one of Aspects 8 to 10, wherein at least one type of thread selected from the group consisting of warp threads, weft threads and threads for engaging elements is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 265°C (preferably 250 to 257°C).
[Aspect 12]
A method for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to any one of aspects 8 to 11, wherein the warp yarns, weft yarns and engaging element yarns are all yarns made of a copolymerized polyethylene terephthalate resin containing, as copolymerization components, 1.0 to 2.0 mol % of isophthalic acid based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % of diethylene glycol based on the total amount of diols.
[Aspect 13]
A method for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to any one of aspects 8 to 12, wherein the dry heat shrinkage at 200° C. of the yarns made of polyethylene terephthalate-based resin used as the warp yarns, weft yarns, and engaging element yarns is in the range of 10 to 35%.
Aspect 14
A method for producing a polyethylene terephthalate-based woven fabric surface fastener according to any one of Aspects 8 to 13, wherein through holes are formed in the binder resin layer.
[Aspect 15]
A method for producing a textile product with a polyethylene terephthalate-based woven fabric hook-and-loop fastener, comprising attaching the polyethylene terephthalate-based woven fabric hook-and-loop fastener according to any one of aspects 3 to 5 to a textile product made of a polyethylene terephthalate-based resin, and simultaneously dyeing the textile product in the attached state to the same color using a disperse dye.
Furthermore, one aspect of the present invention may be a polyethylene terephthalate-based woven fabric surface fastener having a base fabric woven with warp threads, weft threads, and threads for engaging elements, a first surface of the base fabric being the front side and a second surface being the back side, threads for engaging elements being woven into the base fabric parallel to the warp threads, and a number of hook-shaped and/or loop-shaped engaging elements formed from the threads for engaging elements and rising from the first surface of the base fabric being present on the front surface (or first surface) of the base fabric, and the warp threads, weft threads, and threads for engaging elements are all composed of threads made of polyethylene terephthalate-based resin, the woven fabric surface fastener being characterized in that it satisfies all of the following configurations 1) to 4).

1) A binder layer made of a polyethylene terephthalate resin having a melting point of 160 to 210°C and copolymerized with isophthalic acid is directly bonded to the back surface (or second surface) of the base fabric opposite to the surface on which the engaging elements are present, and a part of the resin of the binder layer penetrates into the base fabric;
2) The warp yarn is made of a polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 250 to 257°C;
3) At a portion where the yarn for the engaging element is under the weft yarn on the second surface of the base fabric, the yarn for the engaging element is bonded to the binder layer by a resin constituting the binder layer present on the second surface of the base fabric;
4) At the locations where the warp yarns and the yarns for the engaging elements cross the weft yarns on the first surface of the base fabric, the warp yarns and the yarns for the engaging elements are not bonded to the weft yarns;
It is.

In one aspect of the present invention, the method for producing a woven fabric hook-and-loop fastener comprises a base fabric made of warp yarns made of polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 250 to 257°C, and weft yarns and yarns for engaging elements made of polyethylene terephthalate resin, a first surface of the base fabric being the front side and a second surface being the back side, the yarns for engaging elements being woven into the base fabric parallel to the warp yarns, the first surface of the base fabric has a number of hook-shaped and/or loop-shaped engaging elements formed from the yarns for engaging elements and rising from the first surface of the base fabric, and a binder layer made of polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C integrated with the back surface (second surface) of the base fabric opposite the surface on which the engaging elements are present, characterized in that the method for producing a polyethylene terephthalate woven fabric hook-and-loop fastener comprises the steps A, B, and C described below, which are carried out in this order.

[Step A] A step of weaving a loop fabric by weaving threads for engaging elements parallel to the warp threads and simultaneously causing the threads for engaging elements to rise in regular loops from the first surface of the base fabric at the locations where the threads cross the weft threads,
[Step B] A step of attaching the resin for the binder layer to the second surface of the base fabric of the loop woven fabric and densifying the loop woven fabric to allow a part of the resin for the binder layer to penetrate into the inside of the back surface of the base fabric, and then cooling and solidifying the binder resin;
[Step C] When the loop is made of a monofilament yarn, a step of heating the first surface side of the base fabric to 180 to 230°C, cooling it, and cutting one leg of the loop to make the loop into a hook-shaped engaging element.

As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms "at least one," unless the content clearly dictates otherwise. As used herein, the terms "and/or," "at least one," and "one or more" include any and all combinations of the associated listed items.

It should be noted that any combination of at least two components disclosed in the claims and/or the specification and/or the drawings is also included in the present invention. In particular, any combination of two or more of the claims described in the claims is also included in the present invention.

In one embodiment of the PET-based woven hook-and-loop fastener of the present invention, a layer (hereinafter sometimes abbreviated as PET resin layer) made of PET-based resin (hereinafter sometimes abbreviated as PET resin (A) or simply resin (A)) with a melting point of 160 to 210°C is provided on the second surface of the base fabric by copolymerizing IPA as a binder layer, and the thread for the engaging element is directly bonded and fixed by this binder layer (or PET resin layer), thereby increasing the engaging force of the engaging element.

The PET resin layer integrated with the second surface of the base fabric is made of a resin copolymerized with IPA to have a melting point of 160-210°C. Unlike typical PET-based resins, which are rigid, this type of resin is highly flexible. Furthermore, since resin (A) of the PET resin layer is not present on the surface of the first surface of the base fabric, even though this type of flexible resin is integrated with the second surface of the base fabric, it is possible to prevent the woven hook-and-loop fastener from becoming hard overall.

In one embodiment of the woven hook-and-loop fastener of the present invention, where the thread for the engaging element is under the weft on the second surface side of the base fabric, the thread for the engaging element is adhered to the same layer by the PET resin (A) constituting the PET resin layer (or binder layer) present on the second surface side of the base fabric, but where the warp thread and the thread for the engaging element straddle the weft on the first surface side of the base fabric, the warp thread and the thread for the engaging element are not adhered to the weft. Therefore, the thread for the engaging element is adhered and fixed to the binder layer only at the location exposed on the second surface side of the base fabric and in the vicinity thereof, and the engaging element is not substantially fixed to the base fabric by the same resin from the adhesively fixed location to the first surface of the base fabric.

In this case, since the engaging elements are not glued and fixed to the base fabric by the PET resin (A) at the points where they rise from the surface of the base fabric, when they are used as a hook-and-loop fastener, even if pressure is applied to the engaging elements from above, the engaging elements can spread laterally on the surface of the base fabric and within the base fabric, tilt, or sink into the base fabric, etc., and the pressure from above can be dispersed. Therefore, the flexibility of the PET resin (A) in the PET resin layer, combined with the fact that the same resin does not fix the threads on the first surface side of the base fabric, improves the flexibility of the entire base fabric.

In one embodiment of the woven hook-and-loop fastener of the present invention, when the warp and weft threads constituting the base fabric from the first surface side to near the second surface side are not adhesively fixed except by the PET resin layer on the second surface side of the base fabric, the area near the first surface side in particular is not substantially adhesively fixed, which further improves the flexibility of the entire base fabric.

In one embodiment of the woven hook-and-loop fastener of the present invention, at least one of the warp and weft threads constituting the base fabric is made of IPA-copolymerized PET resin, and the PET resin layer bonded to the second surface of the base fabric is also made of IPA-copolymerized PET resin. As a result, the affinity between the two allows the warp and/or weft threads to be more firmly fused and bonded to the PET resin layer, and the base fabric is less likely to peel off due to repeated engagement and release during use as a hook-and-loop fastener or repeated washing. Furthermore, when the thread for the engaging elements is also made of IPA-copolymerized PET, the effect of preventing peeling between the base fabric and the PET resin layer is further improved.

In the woven hook-and-loop fastener of one embodiment of the present invention, when IPA-copolymerized PET is used for both the warp and/or weft threads and the PET resin layer that constitute the woven hook-and-loop fastener, the IPA-copolymerized PET resin can lower the melting point without significantly impairing the film properties of the threads and binder layers, and can provide threads and binder layers that have excellent bonding strength by heat fusion, as well as excellent flexibility and dyeability. In a particularly preferred embodiment, when IPA is copolymerized in the case of threads, the threads can be made to shrink significantly when heated, so that when a molten PET resin layer or the like is integrated with the second surface of the base fabric, the base fabric is thermally shrunk by heating during integration, and as a result, the PET resin (A) integrated with the second surface of the base fabric can be prevented from penetrating the base fabric and flowing or seeping out to the surface side.

Furthermore, IPA copolymerized PET is used as a raw material for PET bottles to provide anti-fogging properties to the PET bottles, and therefore recycled yarns manufactured using resin recovered from PET bottles as a raw material to appropriately match the modification amount and melting point of the present invention can also be recycled and reused as yarns that make up the hook-and-loop fastener of the present invention.

Furthermore, in one embodiment of the woven hook-and-loop fastener of the present invention, the warp threads, weft threads, threads for the engaging elements, and the PET resin layer (or binder layer) integrated on the second surface are all made of PET-based threads or resins, preferably IPA copolymerized PET-based resins, and therefore a woven hook-and-loop fastener made of such threads or layers can improve recyclability. For example, PET-based fibers are currently used in many clothing items and everyday items such as gloves and shoes, and when the polyethylene terephthalate-based woven hook-and-loop fastener of the present invention is attached to these PET-based textile products, it is not necessary to peel the woven hook-and-loop fastener of the present invention from the textile product, and it becomes possible to provide the textile product with the hook-and-loop fastener attached to the textile product in a recycling system.

Moreover, in one embodiment of the woven hook-and-loop fastener of the present invention, the warp threads, weft threads, threads for the engaging elements, and the binder layer on the second surface are all made of PET-based resin, so they can be dyed with ordinary disperse dyes. Moreover, when these threads and layers are made of PET-based resin copolymerized with IPA, there is almost no difference in the dyeing between the base fabric portion of the hook-and-loop fastener and the resin layer integrated with the second surface side when dyed with disperse dyes, and there is no impression that something of a different color is integrated with the second surface side of the base fabric.

In particular, when a PET textile product to which a woven hook-and-loop fastener according to one embodiment of the present invention is attached is dyed with a disperse dye, the textile product and the woven hook-and-loop fastener of the present invention can be dyed the same color at the same time, eliminating the need to dye them separately or to prepare a hook-and-loop fastener that has already been dyed the same color as the polyester textile product.

1 is a cross-sectional view showing a schematic diagram of an example of a woven surface fastener of the present invention. FIG. 2 is a cross-sectional view showing a schematic diagram of another example of the woven fabric surface fastener of the present invention. FIG. 2 is a schematic diagram showing an example of the production of the woven fabric surface fastener of the present invention, particularly a case in which a binder layer is pressed in a molten state onto the second surface side of a base fabric.

The present invention will be described in detail below. First, the PET-based woven surface fastener of the present invention can be broadly divided into three types: a hook surface fastener in which only hook-shaped engaging elements are present on the first surface of the base fabric, a loop surface fastener in which only loop-shaped engaging elements are present on the first surface of the base fabric, and a hook-loop coexisting surface fastener in which both hook-shaped engaging elements and loop-shaped engaging elements are present coexistently on the first surface of the base fabric.

Among these, the hook surface fastener is mainly formed from monofilament yarn for the hook-shaped engaging element, multifilament yarn for the warp thread and multifilament yarn for the weft thread, and a PET resin layer fusion-bonded to the second surface side of the base fabric. The loop surface fastener is mainly formed from multifilament yarn for the loop-shaped engaging element, multifilament yarn for the warp thread and multifilament yarn for the weft thread, and a PET resin layer fusion-bonded to the second surface side of the base fabric. Furthermore, the hook-loop coexisting type surface fastener, in which the hook-shaped engaging element and the loop-shaped engaging element coexist on the same surface, is mainly formed from monofilament yarn for the hook-shaped engaging element, multifilament yarn for the loop-shaped engaging element, multifilament yarn for the warp thread and multifilament yarn for the weft thread, and a PET resin layer fusion-bonded to the second surface side of the base fabric.

The warp yarn (e.g., multifilament yarn for warp), weft yarn (e.g., multifilament yarn for weft) and thread for engaging element (e.g., monofilament yarn for hook-shaped engaging element, multifilament yarn for loop-shaped engaging element) must be fibers substantially composed of PET-based resin because they can prevent waving due to water absorption and moisture absorption, can be firmly bonded by heat fusion with the PET resin layer bonded to the second surface side, the threads do not yellow due to the heat when fusion bonding the PET resin layer to the second surface of the base fabric, polyester-based fibers are used in all clothing and daily necessities, and when these products are dyed, the attached hook-and-loop fastener can be dyed the same color at the same time, and the hook-and-loop fastener can be sent to the recycling system with the hook-and-loop fastener attached to the polyester-based fiber product. Here, "fiber substantially composed of PET-based resin" means a fiber in which the ratio of PET-based resin in the fiber is, for example, 90% or more, preferably 98% or more, and more preferably 100% or more, and may be a PET-based fiber that is preferably a non-composite fiber. .

If the warp and/or weft are multifilament yarns made of PET resin, they can be recycled. For example, they may be multifilament yarns made of PET resin with a melting point of 250-265°C. However, preferably, the warp and/or weft are multifilament yarns made of PET resin with a melting point of 250-257°C and with which IPA may be copolymerized, because they can achieve the above requirements to a high degree. Furthermore, it is preferable to use multifilament yarns made of PET resin with a melting point of 250-257°C and with which IPA may be copolymerized as the yarn for the loop-shaped engaging element, and monofilament yarns made of PET resin with a melting point of 250-257°C and with which IPA may be copolymerized as the yarn for the hook-shaped engaging element.

When copolymerized PET is used as the resin that constitutes the threads and layers that make up the hook-and-loop fastener, if IPA is used as the copolymerization unit on the dicarboxylic acid side, the melting point can be lowered without significantly impairing the excellent thread properties, layer performance, ease of molding, etc., that PET possesses, and it is also preferable that threads and films with excellent joining strength by heat fusion, excellent flexibility and dyeability can be obtained, threads with high heat shrinkability can be obtained, and threads and layers with excellent flexibility and dyeability can be obtained.

The warp threads are preferably made of IPA-copolymerized PET multifilament yarns having ethylene terephthalate units as the main repeating units, made of a PET polymer copolymerized with IPA, and having a melting point of 250 to 257°C. Having a melting point within this range allows the weaving process to be carried out well, prevents the warp threads from becoming excessively stiff, and improves the feel of the surface of the woven hook-and-loop fastener. Furthermore, if the hook-and-loop fastener is dyed with a disperse dye after being made into a hook-and-loop fastener, it is possible to suppress the occurrence of dye differences with the layer made of PET resin (A) integrated with the second surface side of the base fabric, promoting uniform coloring as a hook-and-loop fastener and giving the impression of an integrated overall structure.

Preferably, the warp yarn is a multifilament yarn made of a PET resin in which 1.0 to 2.0 mol % of IPA is copolymerized with respect to the total amount of dicarboxylic acids, and in such a case, the above-mentioned features can be achieved to an even greater extent. More preferably, yarn is made of copolymerized PET containing 1.0 to 2.0 mol % of IPA with respect to the total amount of dicarboxylic acids and 2.0 to 3.5 mol % of DEG (diethylene glycol) with respect to the total amount of diols as copolymerization components.

DEG normally occurs naturally when PET is polymerized and is contained in PET, but the amount of 2.0 to 3.5 mol% specified in this invention is greater than the amount that occurs naturally when PET for fiber is polymerized. Therefore, for the yarn used in this invention, it is preferable to use a PET-based resin obtained by adding DEG as part of the raw material when polymerizing PET for fiber. However, PET-based resins for PET bottles may contain the above amount of DEG as a copolymerization component, and yarn obtained from such raw materials may be used as appropriate.

Furthermore, it is preferable that the PET resin constituting the warp yarn is substantially free of copolymerization components other than IPA. Note that the copolymerization components other than IPA mentioned here do not include DEG or triethylene glycol, which are naturally generated in small amounts when terephthalic acid, IPA, and ethylene glycol are condensed and polymerized, or benzoic acid, which is used in small amounts as a terminal terminator during the condensation polymerization of PET polymers.

The base fabric of these hook-and-loop fasteners may contain small amounts (for example, 5% by weight or less, preferably 1% by weight or less) of other PET-based yarns, if necessary.

As for the thickness (fineness) of the multifilament yarns that make up the warp threads, multifilament yarns consisting of 20 to 60 filaments and having a total decitex of 100 to 300 decitex are preferred, as this provides the flexibility of the resulting hook-and-loop fastener and a dense base fabric that can prevent the resin of the resin layer integrated with the second surface from reaching the first surface side, and multifilament yarns consisting of 24 to 48 filaments and having a total decitex of 150 to 280 decitex are particularly preferred. Note that the above thickness refers to the thickness of the yarns used for weaving before they are heat-shrunk.

The weft thread must be made of a PET resin, and may be a multifilament thread made of an IPA-copolymerized PET resin having a melting point of, for example, 250-265°C, preferably 250-257°C, in which IPA is copolymerized. In particular, when the melting point of the PET resin constituting the weft thread is 250-257°C, this is preferable because it prevents the base fabric from being excessively compressed while preventing the weft thread from becoming excessively stiff, gives the first surface of the woven hook-and-loop fastener a soft feel, and, when dyed with a disperse dye, is less likely to cause a dye difference between the base fabric portion of the hook-and-loop fastener and the resin layer integrated with the second surface.

Preferably, as with the warp yarn, the weft yarn is a multifilament yarn made of copolymerized PET containing 1.0 to 2.0 mol % IPA based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % DEG based on the total amount of diols as copolymerization components, and in such a case, the above-mentioned advantages of the present invention can be achieved to a greater extent.

As for the thickness of the multifilament yarn that constitutes the weft, a multifilament yarn consisting of 10 to 72 filaments with a total decitex of 80 to 300 decitex is preferred for the same reasons as for the warp yarn, and a multifilament yarn consisting of 18 to 56 filaments with a total decitex of 90 to 260 decitex is particularly preferred. Note that the above thickness is the thickness of the yarn used for weaving before it is heat-shrunk.

The multifilament yarns used for the warp and weft threads must not melt due to the heat applied when fusing and bonding the PET resin layer to the second surface of the base fabric, and further, in the case of hook-shaped engaging elements, must not melt due to the heat applied to the engaging element yarns to fix the hook shape. This is necessary in order to soften the feel of the woven base fabric surface, and for this reason, it is preferable that the warp and weft threads do not contain any low-melting point components that melt at temperatures below 250°C.

In the hook-and-loop fastener of the present invention, when the engaging elements are hook-shaped engaging elements, the hook-shaped engaging elements are required to have so-called hook shape retention and rigidity, i.e., the hook shape is not stretched by a light force, and for this reason, a thick monofilament thread is used. In the present invention, the monofilament thread is preferably formed from a PET-based resin, which has excellent hook shape retention properties.

This monofilament thread must be made of a PET-based resin, and may be a monofilament thread made of an IPA-copolymerized PET-based resin having a melting point of, for example, 250-265°C, preferably 250-257°C, in which IPA is copolymerized. In particular, when the melting point is 250-257°C, the hook-shaped engaging elements are easily tilted over and fixed in this state when the PET resin layer is melt-bonded to the second surface side of the base fabric, which not only prevents the engaging elements from losing their uprightness, but also prevents the engaging elements from becoming excessively rigid, and furthermore, by reducing the thickness of the monofilament thread, the feel of the first surface of the woven hook-and-loop fastener can be softened.

Preferably, the monofilament yarn for the hook-shaped engaging element is made of copolymerized PET containing, as copolymerization components, 1.0 to 2.0 mol % IPA based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % DEG based on the total amount of diols. In such a case, the feel of the first surface of the woven surface fastener is improved, and furthermore, the thick monofilament yarn can be dyed deep into the fabric by dyeing with a disperse dye, with little difference in dyeing with the resin layer integrated with the second surface side of the base fabric. Furthermore, with the hook-shaped engaging element dyed in this manner, even if the surface of the hook-shaped engaging element is worn away by repeated engagement and peeling to expose the inner layer of the hook-shaped engaging element, the inner layer of the monofilament is not noticeable.
It is preferable that the PET polymer constituting the weft yarn or the yarn for the engaging element does not contain any copolymerization component other than IPA as a copolymerization component on the dicarboxylic acid side.

The thickness of such monofilament thread for hook-shaped engagement elements made of PET resin is preferably 0.15 to 0.22 mm in diameter in terms of engagement strength and ability to prevent the resin of the resin layer that densifies the base fabric and integrates it with the second surface from reaching the first surface, and more preferably 0.16 to 0.20 mm in diameter. In order to increase the engagement strength, the cross-sectional shape of the monofilament may be an irregular cross-sectional shape, typically a polygonal shape such as a triangle or a square. Note that this thickness is the value before the monofilament thread is thermally shrunk, as described above.

In the hook-and-loop fastener of the present invention, when the engaging elements are loop-shaped engaging elements, the loop-shaped engaging elements are required to be able to maintain a loop shape that spreads laterally, and for this purpose, as in the case of hook-shaped engaging elements, it is preferable to use a multifilament yarn made of a PET resin having a melting point of, for example, 250 to 265°C, preferably 250 to 257°C, and copolymerized with IPA.

In particular, when the melting point is 250 to 257°C, the uprightness of the loop-shaped engaging elements is well maintained when the PET resin layer is melt-bonded to the second surface side of the base fabric, and even if the loop-shaped engaging elements are repeatedly engaged and released, the vertically stretched loop shape can be well restored to the original horizontally expanded loop shape, and the repeated engaging force can be well maintained.

More preferably, the multifilament yarn is made of copolymerized PET containing 1.0 to 2.0 mol % IPA based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % DEG based on the total amount of diols as copolymerization components. In such a case, the feel of the surface of the woven hook-and-loop fastener is improved, and further, by dyeing with disperse dyes under mild conditions, the engaging elements are also dyed in the same way.

As for the thickness of the multifilament yarn constituting the thread for the loop-shaped engaging element, a multifilament yarn consisting of 5 to 15 filaments and having a total decitex of 150 to 500 decitex is preferable, as this can prevent the resin of the resin layer that is integrated with the second surface as the base fabric becomes dense from reaching the first surface side, and a multifilament yarn consisting of 6 to 12 filaments and having a total decitex of 200 to 400 decitex is particularly preferable. As with the hook-shaped engaging element, the cross-sectional shape of the monofilament may be an irregular cross-sectional shape, such as a polygonal shape such as a triangle or a square, in order to increase the engaging force. Note that the above thickness is the thickness of the yarn used for weaving before heat shrinkage.

The melting point of the PET resin as defined in this invention means the melting peak temperature obtained by DSC measurement, specifically, when about 6.5 mg of thread removed from the hook-and-loop fastener and dried, or resin scraped off from the resin layer on the second surface side and dried, is placed in an aluminum cell and nitrogen is flowed at 50 ml/min in a nitrogen atmosphere using a differential calorimeter, and the temperature is raised from about 30°C to 300°C at a heating rate of 50°C/min in this state, that is, the melting point means the apex temperature of the endothermic peak near the melting point of the 1st heating. Measurements are performed on 5 randomly removed pieces of thread or 5 scraped pieces of film, and the average of the 5 values obtained is taken, excluding the minimum and maximum values.

Also, as described below, a binder layer, i.e., a layer made of PET resin (A) copolymerized with IPA and having a melting point of 160 to 210°C, is provided on the second surface side of the base fabric of the hook-and-loop fastener.

The above-mentioned multifilament yarn for warp, multifilament yarn for weft, monofilament yarn for hook-shaped engaging elements, or multifilament yarn for loop-shaped engaging elements are used to manufacture a woven hook-and-loop fastener by carrying out the following steps A, B, and C in this order, as described above.

[Step A] A step of weaving a loop fabric by weaving threads for engaging elements parallel to the warp threads and simultaneously causing the threads for engaging elements to rise in regular loops from the first surface of the base fabric at the locations where the threads cross the weft threads,
[Step B] A step of adhering a PET resin (A) for a binder layer to the back side of the loop fabric (i.e., the second surface side of the base fabric);
[Step C] When the loop is made of a monofilament yarn, a step of heating the first surface of the loop fabric (or the first surface of the base fabric) to 180 to 230°C, followed by cooling, and then cutting one leg of the loop to form the loop into a hook-shaped engaging element.

First, to explain step A above, the weave structure of the woven fabric is preferably a plain weave in which the threads for the engaging elements are part of the warp threads, and these threads for the engaging elements are woven parallel to the warp threads and rise from the base fabric surface midway through the weave. When the threads for the engaging elements are monofilament threads, the weave structure is such that they form loops and jump over one to three warp threads and slip between the warp threads. On the other hand, when the threads for the engaging elements are multifilament threads, the weave structure in which they form loops without crossing the warp threads or crossing one warp thread and are parallel to the warp threads is preferable in terms of appearance, as the loop faces tend to face in the same direction, and furthermore, in the case of loops for hook-shaped engaging elements, one side of the thread can be cut efficiently and reliably, and furthermore, the hook-shaped engaging element and the loop-shaped engaging element tend to engage with each other, which is preferable.

The weave density of the warp yarns is preferably 35 to 80 yarns/cm after heat shrinkage, and the weave density of the weft yarns is preferably 12 to 30 yarns/cm after heat shrinkage, because this densifies the base fabric and prevents the resin of the resin layer integrated with the second surface from reaching the first surface side. The weight ratio of the weft yarns is preferably 15 to 40% of the total weight of the yarns for the hook-shaped engaging elements, the yarns for the loop-shaped engaging elements, the warp yarns and the weft yarns that constitute the woven fabric surface fastener.
In addition, in the woven surface fastener of the present invention, the height of the hook-shaped engaging elements is preferably 1.2 to 1.8 mm from the surface of the woven base fabric, and the height of the loop-shaped engaging elements is preferably 1.9 to 3.0 mm from the surface of the woven base fabric, from the standpoint of engaging force and also from the standpoint of the resistance of the engaging elements to collapsing.

The density of hook-like engaging elements in a hook surface fastener is preferably 30 to 70 elements/ ^cm2 on the basis of the base fabric portion where the engaging elements are present and after heat shrinkage, the density of loop-like engaging elements in a loop surface fastener is preferably 30 to 70 elements/ ^cm2 on the basis of the same basis and after heat shrinkage, and the total density of hook-like engaging elements and loop-like engaging elements in a hook-loop coexisting type surface fastener is preferably 30 to 70 elements/ ^cm2 on the basis of the same basis and after heat shrinkage. In the hook-loop coexisting type surface fastener, the ratio of the number of hook-like engaging elements to the number of loop-like engaging elements is preferably in the range of 40:60 to 60:40.

In addition, in a hook surface fastener, the number of monofilament threads for the hook-shaped engaging elements is preferably about 2 to 8 threads per 20 warp threads (including monofilament threads for the hook-shaped engaging elements), and in a loop surface fastener, the number of multifilament threads for the loop-shaped engaging elements is preferably about 2 to 8 threads per 20 warp threads (including monofilament threads for the hook-shaped engaging elements).

Furthermore, in the case of a hook-and-loop parallel type surface fastener, the total number of monofilament yarns for the hook-shaped engaging elements and multifilament yarns for the loop-shaped engaging elements is preferably 2 to 8 per 20 warp yarns (including monofilament yarns for the hook-shaped engaging elements and multifilament yarns for the loop-shaped engaging elements), and the ratio of the number of monofilament yarns for the hook-shaped engaging elements and multifilament yarns for the loop-shaped engaging elements is preferably in the range of 40:60 to 60:40.

In addition, when forming the loop for the hook-shaped engaging element, in order to facilitate the formation of loops for the hook-shaped engaging element of uniform height, a method may be used in which multiple metal rods are placed on the base fabric parallel to the warp thread at the position where the thread for the hook-shaped engaging element straddles the warp thread, the thread for the engaging element is passed through the top of the metal rods to form a loop, and the metal rods are then pulled out of the loop after the loop is formed.

The hook-and-loop fastener fabric thus obtained (hereinafter, may be referred to as loop fabric) is then sent to the above-mentioned step B. There are no particular limitations to step B, so long as the thread for the engaging element can be bonded and fixed by the resin of the binder layer.

For example, attached FIG. 3 is a schematic diagram showing an example of an apparatus that can efficiently carry out this step B. The back side of the loop fabric, i.e., the second side of the base fabric, may be simply referred to as the second side of the loop fabric hereinafter. FIG. 3 is a schematic diagram showing how a PET resin layer with a melting point of 160 to 210°C is pressed in a molten state onto the second side of the loop fabric woven in the above step A. This step B causes a molten film of PET resin (A) with a melting point of 160 to 210°C to be directly pressed onto the second side of the loop fabric, and a portion of the molten PET resin (A) is pressed (penetrated) into the base fabric on the second side of the loop fabric.

In the present invention, when a portion of the resin of the binder layer penetrates into the base fabric, this means that a portion of the resin constituting the binder layer penetrates into the recessed portion on the second surface side of the base fabric, and represents a state in which the resin (A) penetrates into the recessed portion (8) shown in Figures 1 and 2. Note that the recessed portion is formed so that the warp threads or the threads for the engaging elements rise above the weft threads on the first surface side. For example, when a portion of the resin constituting the PET resin layer penetrates into the base fabric, a method is preferably used in which the two are pressed together when integrating the molten film of resin (A) with the second surface side of the loop fabric.

Preferably, when the warp, weft and engaging element threads have a dry heat shrinkage rate at 200°C of 10 to 35%, the heat generated when the molten film of resin (A) is integrated with the second surface side of the loop fabric causes the threads constituting the loop fabric to shrink, further densifying the fabric, thereby blocking the weave of the fabric and preventing the molten resin (A) from penetrating the first surface side of the base fabric or seeping out to the surface of the first surface, and remaining in the recessed portions. As a result, the layer of resin (A) is firmly bonded to the second surface of the base fabric, and the first surface side of the base fabric does not have the inter-thread fixing caused by resin (A), so that flexibility is not lost. More preferably, the warp has a dry heat shrinkage rate at 200°C of 20 to 30%, the weft has a shrinkage rate of 15 to 30%, and the engaging element threads have a shrinkage rate of 20 to 30%.

Furthermore, if the dry heat shrinkage rate is high, when the resin layer is integrated with the second surface of the base fabric, the heat causes the multifilament yarns constituting the loop fabric to shrink in the length direction, and the cross-sectional shape becomes thicker and flatter in the horizontal direction as shown by the weft yarns in Figures 1 and 2. This also causes the weave of the fabric to be blocked, making it difficult for the molten resin (A) to penetrate or seep out to the first surface side of the base fabric, and at the points where the warp yarns and the engaging element yarns cross the weft yarns on the first surface side of the base fabric, the warp yarns and the engaging element yarns are not bonded to the weft yarns; in other words, the warp yarns and the engaging element yarns are not bonded to the weft yarns via the PET resin of the binder layer.

In other words, in step A, the thickness and weaving density of the yarns (warp and/or weft) that make up the loop fabric are increased to weave a dense loop fabric, and in step B, the dense loop fabric is made even denser by heat shrinking the constituent yarns, so that the warp yarns and the engaging element yarns are not bonded to the weft yarns at the locations on the first surface side of the base fabric where they cross the weft yarns.

The 200°C dry heat shrinkage rate specified in this invention is the average value of the shrinkage rates of 10 50 cm long yarns left in a free state in a 200°C atmosphere for 1 minute, and the yarns that have shrunk after 1 minute. Polyester yarns with such dry heat shrinkage rates are sold by synthetic fiber manufacturers with various shrinkage rates, and it is possible to select from among them, or to order yarn with the desired dry heat shrinkage rate from a synthetic fiber manufacturer and have it manufactured, or it can be easily obtained by subjecting commercially available polyester yarns to thermal stretching treatment, etc.

An example of an apparatus capable of carrying out the above-mentioned step B is explained with reference to Fig. 3. A molten film (6) made of PET resin (A) copolymerized with IPA and having a melting point of 160 to 210°C is extruded from a T-die (T), and while the film (6) is kept in a molten state, the molten film ( ₆ ) is pressed against the back surface (or the _second surface of the base fabric) of the loop fabric ( ₁₀ ) for hook-and-loop fastener woven in step A and fed along the surface of the press roll (R 2 ) between a cooling roll (R 1 ) and a press roll (R 2 ) to integrate the two. The integrated product of the two is then run along the cooling roll (R ₁ ) and the molten film (6) is cooled and solidified to form a PET resin layer (6) made of PET resin (A), and the laminate integrated with the PET resin layer (6) on the second surface side of the base fabric is peeled off from the surface of the cooling roll (R ₁ ) by moving it along the surface of a sweeper roll (R ₄ ).

In this case, if a roll having a countless number of fine needle-like projections attached to its surface is used as the press roll (R ₂ ), a large number of holes penetrating the PET resin layer (6) made of resin (A) in the thickness direction are formed, and the presence of these holes makes the hook-and-loop fastener breathable, so that even if the hook-and-loop fastener is used for applications in which it is in close contact with the skin, it is less likely to become steamy, and when it is later dyed with a disperse dye, the dye solution enters and exits through these holes, and the binder layer is easily dyed up to a position close to the second surface side of the base fabric, and when the hook-and-loop fastener is cut, the cross section has the base fabric and the binder layer uniformly dyed, which is preferable in terms of appearance, and is particularly preferable when the dye is a dark color, as it can reduce the heterochromaticity between the base fabric and the binder layer. Here, the dark color means a color with low brightness, and may be, for example, a color with a brightness of 7 or less in the Munsell color system.

As a method for forming a large number of holes penetrating through the layer (6) made of resin (A) in the thickness direction, in addition to the above-mentioned method using a press roll (R2) having countless fine needle-like projections on its surface, it is also possible to use a method in which holes are previously formed in the layer of molten resin (A) before integration, or a method in which holes are formed in the layer of resin (A) present on the second surface side at the subsequent stage of the manufactured hook-and-loop fastener.
Furthermore, as the layer made of resin (A), a fiber sheet such as a nonwoven fabric or a woven or knitted fabric may be used as described below. In the case of a fiber sheet, if a part of the sheet is melted, the other part will remain in a fibrous state and will therefore function as an air hole.

The binder layer integrated with the second surface of the loop fabric is a PET resin (A) with a melting point of 160 to 210°C. If the melting point exceeds 210°C, when the fused film is pressed against the second surface of the loop fabric, the entire hook-and-loop fabric is compressed, and even after it is released, the compressed state is not fully restored, resulting in a hook-and-loop surface that does not have a gentle feel to the touch, and some of the loops for the engaging elements cannot stand up from their fallen state, making it impossible to obtain a hook-and-loop fastener having engaging elements that stand upright from the first surface of the base fabric. If the melting point is less than 160°C, the PET resin (A) of the obtained hook-and-loop fastener is likely to melt and move from the second surface of the hook-and-loop fastener due to ironing during finishing of the textile product, which will impair the pull-out resistance of the engaging elements and damage the attached textile product. Preferably, the melting point of the PET resin (A) is in the range of 170 to 205°C.

In order to make the melting point of the PET resin (A) 160 to 210°C, it is preferable that the PET resin is copolymerized with 15 to 25 mol% IPA, and more preferably, it is a PET resin copolymerized with 16 to 22 mol% IPA.

The PET resin (A) constituting the PET resin layer (binder layer) integrated onto the second surface of the loop fabric is copolymerized with IPA and must have a melting point of 160-210°C. This type of PET resin (A) is an isophthalic acid copolymerized PET obtained by condensation polymerization of terephthalic acid, IPA, and ethylene glycol, and is preferable from the viewpoint of recycling and reuse because it does not contain any copolymerization components other than IPA as a dicarboxylic acid.

In addition, when the crystalline state of the resin to be measured becomes amorphous due to copolymerization or the like and a clear melting point cannot be measured, the softening point is treated as the melting point. The softening point means the minimum temperature at which the chips are fused together to the extent that the boundaries between the chips cannot be determined when the chips are placed in a hot air dryer at a specified temperature and a pressure of 0.1 kg/ ^cm2 is applied for 10 minutes.

The temperature at which the molten PET resin (A) is integrated with the second surface side of the loop fabric is preferably 5 to 25°C higher than the melting point of the PET resin (A). From the viewpoint of improving the pull-out resistance of the engaging elements, if the temperature of the PET resin (A) at the time of integration is in the above range, the molten PET resin (A) can sufficiently penetrate from the second surface of the loop fabric into the structure of the base fabric, and sufficient pull-out resistance of the engaging elements can be obtained, which is preferable. Furthermore, if the temperature of the PET resin (A) at the time of integration is in the above range, it is possible to prevent the molten PET resin (A) from penetrating too deeply toward the first surface side of the base fabric of the loop fabric, for example, to prevent it from being exposed on the first surface side of the base fabric and hardening the entire hook-and-loop fastener fabric, and is particularly preferable because it can prevent the feel of the hook-and-loop fastener surface from becoming hard.

In addition, when the binder layer is integrated with the second surface of the loop fabric, if the pressure applied is too high, the binder layer integrated with the second surface of the base fabric may penetrate from the second surface side to the first surface side of the base fabric. To prevent this, it is preferable to limit the pressure of the cooling roll (R ₁ ) and the press roll (R ₂ ) to about 0.30 to 0.70 MPa.
The basis weight of the binder layer integrated onto the second surface of the loop fabric is, for example, in the range of 30 to 100 g/ ^m2 , preferably 40 to 90 g/ ^m2 , and more preferably 50 to 80 g/ ^m2 , from the viewpoint of the pull-out resistance of the engaging elements and further from the viewpoint of the flexibility of the hook-and-loop fastener.

In the above description, step B is a case where the molten PET resin (A) is formed into a film and integrated in a molten state onto the second surface of the loop fabric, but the present invention is not limited to this case. Other examples of step B include a method in which a fiber sheet or film made of PET resin (A) with a melting point of 160 to 210°C, such as a spunbond nonwoven fabric or meltblown nonwoven fabric, is superimposed onto the second surface of the loop fabric, and heat is applied in this state to melt the fiber sheet or film, which is then pressed onto the second surface of the loop fabric.

In this case, in addition to the method of melt-pressing the entire surface of the hook-and-loop fastener fabric, a method of melt-pressing in spots may also be used. In this case, it is preferable to melt-press in small spots so that the majority of the engaging element threads exposed on the second surface of the hook-and-loop fastener are fixed by the molten material.

In addition to the above-mentioned method of applying a thermoplastic resin to the second surface of the woven fabric, a method is also possible in which a PET resin (A) that is soluble or dispersible in water or an organic solvent is diluted with water or an organic solvent such as ethyl acetate to form a liquid with a solids concentration of about 5 to 60% by mass of the raw material composition, and the polyester resin is applied to the second surface of the woven fabric by coating with a roller coater or spraying, and then dried to form a resin layer on the second surface of the woven fabric. When it is desired to achieve film strength that can withstand a force that tries to pull out the element, which is required when used as a hook-and-loop fastener, by this method, the entire woven hook-and-loop fastener containing the polyester resin applied to the second surface of the woven fabric may be heated to a temperature equal to or higher than the melting point of the applied PET resin (A) to melt it, and the molten PET resin (A) may be coagulated to form a resin film, and the resin film may be used to bond between the fibers in the base fabric portion of the woven fabric. Alternatively, the PET resin (A) may be crosslinked with a melamine resin or the like to obtain a film strength necessary to withstand the force of pulling out the element. When dissolving the applied PET resin (A) and agglomerating the resins to form a resin film, if a sufficient resin film cannot be formed with the amount of resin that can be normally applied with a general coater, multiple coats, such as two coats, may be applied. The shape of the resulting resin layer is not limited as long as it has the effect of adhering the thread for the engaging element, whether it is a continuous phase or a discontinuous layer attached in spots.

By this process B, the thread for the engaging element is fixed by the PET resin (A) in the weave of the second surface side of the loop fabric, and excellent pull-out resistance of the engaging element is obtained. The direct contact of the PET resin (A) with the second surface of the hook-and-loop fabric is necessary for increasing the pull-out resistance of the engaging element and for allowing the hook-and-loop fastener of the present invention to be used in a recycling system. If the second surface of the hook-and-loop fastener fabric is integrated with an adhesive other than the PET resin (A), such as a polyurethane-based, polyacrylic-based, or polyolefin-based adhesive, the presence of this adhesive impairs the recyclability of the hook-and-loop fastener. Furthermore, these adhesives seep not only onto the second surface side of the hook-and-loop fastener base fabric but also onto the first surface side of the hook-and-loop fastener base fabric, hardening the entire hook-and-loop fastener fabric, which impairs the flexibility of the entire hook-and-loop fastener, especially the flexibility of the surface.

The thus obtained fabric for a hook-and-loop fastener, in which a layer of PET resin (A) is integrated with the second surface side of the base fabric, may then be subjected to the above-mentioned step C, if necessary. In step C, when the loops of the loop fabric contain monofilament yarn, that is, in the case of a hook hook fastener or a hook-and-loop coexisting hook-and-loop fastener, the surface on which the loops of the loop fabric are formed (hereinafter sometimes simply referred to as the first surface of the loop fabric) is heated to, for example, 150 to 250°C, preferably 180 to 230°C, and then cooled, and sent to a step in which one leg of the loop is cut to convert the loop into a hook-shaped engaging element. Note that when the loops are made of only multifilament yarn, that is, in the case of a loop hook-and-loop fastener, this step C is not necessary.

The heating of the first surface side of the loop fabric in step C is performed to fix the loop shape of the hook-shaped engaging element. Even if the heating temperature exceeds the melting point of the resin (A), it is possible to control the melting state of the resin (A) by adjusting the heating time as described below. However, it is preferable to heat the loop for the hook engaging element on the first surface side of the loop fabric to 150 to 250°C. If the heating temperature is less than 150°C, the shape of the loop for the hook engaging element will not be fixed sufficiently, and the hook shape of the hook-shaped engaging element cut in the subsequent step of cutting one leg of the loop for the hook engaging element will stretch and become difficult to engage. If the heating temperature exceeds 250°C, the layer made of the resin (A) integrated with the second surface side of the base fabric will melt or soften, exposing the resin (A) on the first surface of the base fabric or making the base fabric entirely film-like, impairing the overall flexibility and the feel of the surface. The preferable range is 180 to 230°C.

The time for such heating is preferably in the range of 20 to 120 seconds. Usually, a method is used in which a hook-and-loop fastener fabric having loops for hook-shaped engaging elements on the first surface of a base fabric and a layer of resin (A) integrated on the second surface of the base fabric is passed through a heating zone maintained at the above temperature at a constant speed.

In this way, after the loop for the hook engaging element present on the first surface of the base fabric is fixed in shape by heat, one leg of this loop is cut to make the loop into a hook-like engaging element. The cutting device used for this purpose is preferably a cutting device structured to cut one leg of the loop for the hook-like engaging element of a fabric for a hook surface fastener or a fabric for a hook and loop coexisting type surface fastener running in the warp direction by the reciprocating motion of a movable cutting blade between two fixed blades. The fabric with one leg of the loop for the hook-like engaging element cut off is used as a hook surface fastener or a hook and loop coexisting type surface fastener.

It should be noted that, although it is not necessary to carry out step C above for loops for loop-shaped engaging elements, it is preferable to form loops and loosen the multifilament yarn so that it can be easily engaged with the hook-shaped engaging elements. Specifically, it is preferable to use a method in which the surface of the hook-and-loop fastener having the loop-shaped engaging elements is rubbed with card clothing or the like to loosen the bundle of multifilament yarn that forms the loop.

In the PET-based woven hook-and-loop fastener obtained in this manner, the threads for the engaging elements are directly bonded and fixed by the resin in the binder layer, or, where the threads for the engaging elements slip under the weft threads on the second surface side of the base fabric, the threads for the engaging elements are bonded to the layer by the PET resin (A) constituting the layer on the second surface side of the base fabric, thereby preventing the engaging elements from being pulled out from the surface of the base fabric.

The thickness of the binder layer may be, for example, 20 to 80 μm, preferably 30 to 70 μm, and more preferably 40 to 60 μm. The thickness of the binder layer is a value measured by the method described in the examples below.

Furthermore, the PET-based woven hook-and-loop fastener thus obtained is preferably dyed. The dyeing is preferably carried out by a high-temperature, high-pressure dyeing method using a disperse dye, which is widely used for dyeing polyester-based textile products. That is, the PET-based woven hook-and-loop fastener of the present invention is wound in a long roll, specifically a hook-and-loop fastener having a length of 50 to 300 m, this roll is placed on a partition plate with holes, and several such partition plates with the rolled material placed on them are stacked vertically and inserted into a dyeing tank, and a dye solution is circulated inside the tank to bring the hook-and-loop fastener into contact with the dye solution.

Specific dyeing conditions include dyeing at about 120 to 140°C for about 20 to 120 minutes. There are no particular restrictions on the type of disperse dye used for dyeing, and any disperse dye that has traditionally been used to dye polyester fibers can be used, such as monoazo, diazo, and anthraquinone disperse dyes, as well as nitro, styryl, and methine disperse dyes.

In this case, if a large number of holes are made in the thickness direction in the layer of resin (A) integrated with the second surface side of the base fabric of the woven hook-and-loop fastener, the presence of these holes allows the dye solution to penetrate the layer of resin (A) and dye up to a location close to the second surface side of the woven base fabric, and when the hook-and-loop fastener is cut, the cross section is dyed uniformly, which is preferable in terms of appearance. This type of dyeing is preferable in that it improves appearance, especially in dark colors.

Moreover, in the case of the woven hook-and-loop fastener of the present invention, the resin (A) integrated on the second surface side of the base fabric has a large amount of amorphous regions due to the IPA units greatly disrupting the PET crystal structure, and therefore when dyed with a disperse dye, the dye molecules can easily penetrate into these amorphous regions, and therefore the hook-and-loop fastener is easily dyed. Therefore, even if the hook-and-loop fastener is fixed to the object by a method that exposes the layer made of the resin (A) on the second surface side of the base fabric, there is no need to worry about the color tone.

Fig. 1 is a schematic diagram showing a cross section of a hook surface fastener, which is an example of a PET-based woven surface fastener of the present invention. Also, Fig. 2 is a schematic diagram showing a cross section of a loop surface fastener, which is another example of a PET-based woven surface fastener of the present invention. In both diagrams, the cross section is taken parallel to the warp threads and is cut so that the warp threads appear in the cross section, and the threads for engaging elements are present at the back of the cross section.
As can be seen from these figures, in the hook-and-loop fastener of the present invention, the warp threads (2) rise and fall above and below the weft threads (1) at the center to form the base fabric (5). The threads for the engaging elements are woven into the base fabric (5) parallel to the warp threads and rise regularly in places from the first surface of the base fabric. Here, the upper side refers to the first surface side, and the lower side refers to the second surface side.

In Fig. 1, the engaging element is a hook-shaped engaging element (3), and in Fig. 2, the engaging element is a loop-shaped engaging element (4). In the case of a hook-shaped engaging element (3), one leg of the loop is cut off to form a hook shape. The warp thread (2) and weft thread (1) are made of multifilament yarn (although in Figs. 1 and 2, the warp thread is shown as one, it is actually an assembly of many thin filament yarns), and the thread for the loop-shaped engaging element is also made of multifilament yarn. And in order to increase the possibility of the loop-shaped engaging element engaging with the hook-shaped engaging element, the bundle of multifilament yarn is loosened at the loop portion.

In the PET-based woven fabric hook-and-loop fastener of the present invention, a layer (6) made of resin (A) is directly integrated with the second surface side of the base fabric, and a portion of the resin (A) fills the depressions (8) created by the intersections of the textile yarns, as shown as depressions (8) in these figures, and as a result, the layer (6) made of resin (A) is firmly integrated with the base fabric.

The layer (6) made of resin (A) has many holes (7) that penetrate the layer. For example, the diameter of the through holes may be 10 to 1000 μm, and preferably 50 to 500 μm. At the location where the thread for the engaging element is under the warp thread on the second surface side of the base fabric (the back location marked with the symbol 9 in Figures 1 and 2), the thread for the engaging element is adhered and fixed to the layer made of resin (A) present on the second surface side of the base fabric, thereby preventing the engaging element from being pulled out from the surface of the base fabric. At the first surface side of the base fabric, i.e., the location where the warp thread is above the weft thread, the warp thread and the thread for the engaging element cross the weft thread but are not adhered to the weft thread, so that the surface of the hook-and-loop fastener has a soft and gentle feel.

In addition, the pull-out force of the engaging element referred to in this invention is the measured value of the maximum strength when the engaging element is pulled out from the base fabric of the hook fastener. In the case of a hook hook fastener, it means the value of the pull-out force of the hook-shaped engaging element, and in the case of a loop hook fastener, it means the value measured when the thread that forms the loop engaging element floats up to the first surface of the woven base fabric as a loop, and then the thread is cut at the point where it floats up, and the pull-out force of the loop engaging element is measured. In this invention, 10 of these were randomly selected, their pull-out forces were measured, and the average value was used.

The PET-based woven hook-and-loop fastener of the present invention can be used in fields where conventional woven hook-and-loop fasteners are used, such as clothing, shoes, bags, hats, gloves, blood pressure monitors, supports, various toys, small items, curtains, and a wide range of other fields. It is particularly suitable for fields where a good feel and flexibility are required and where the hook-and-loop fastener is attached to fabric or sheets by sewing, such as clothing, shoes, bags, hats, gloves, supports, etc.

In particular, it is suitable as a fastening material for polyester textile products that are dyed with disperse dyes, and is suitable for applications in which the PET-based woven hook-and-loop fastener of the present invention is attached to the polyester textile product by sewing or the like, and then the textile product and the hook-and-loop fastener are dyed simultaneously with the textile product using disperse dyes, i.e., so-called piece-dyeing applications. Furthermore, the PET-based woven hook-and-loop fastener of the present invention is suitable for applications in which the textile product is sent to a recycling system while still attached, without being removed from the textile product after use.

The present invention will now be described more specifically with reference to examples.
In the examples, the engaging force of the hook-and-loop fastener was measured in accordance with JIS L 3416:2000.
As the mating hook fastener when measuring the engaging force, when the hook fasteners in the examples and comparative examples were hook hook fasteners, B2790Y (manufactured by Kuraray Fastening Co., Ltd.) was used as a loop hook fastener, when the hook fasteners in the examples and comparative examples were loop hook fasteners, A8693Y (manufactured by Kuraray Fastening Co., Ltd.) was used as a hook hook fastener, and when the hook fasteners in the examples and comparative examples were hook-loop parallel type hook fasteners, the same hook-loop parallel type hook fasteners were used.

In the following examples and comparative examples, the copolymerization ratio of IPA and DEG means the ratio to the total moles of the dicarboxylic acid component of the polymerization raw material for IPA, and similarly means the ratio to the total moles of the diol component for DEG. In the following tables, "Tm" means the melting point, and "Dsr200°C" means the dry heat shrinkage rate at 200°C.

Example 1
The following threads were prepared as the warp and weft threads constituting the base fabric of the hook surface fastener and the monofilament threads for the hook-shaped engaging elements, and the following resin was prepared as the PET resin integrated into the second surface of the surface fastener.
[Warp threads]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 1.3 mol% and DEG 2.5 mol%)
Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 256.0°C
・200℃ dry heat shrinkage rate: 22.1%

[Weft thread]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 1.3 mol% and DEG 2.5 mol%)
Total decitex and filament count: 198 dtex, 48 filaments Melting point: 255.4°C
・200℃ dry heat shrinkage rate: 22.3%
[Monofilament yarn for hook-shaped engaging element]
Monofilament yarn made of copolymerized PET (copolymerization ratio: 1.3 mol% IPA and 2.6 mol% DEG)
Diameter: 0.19 mm
Melting point: 255.0°C
・200℃ dry heat shrinkage rate: 24.2%
[PET-based resin integrated into the second surface of the hook-and-loop fastener]
・Resin made of copolymerized PET (copolymerization ratio: IPA is copolymerized at 18 mol%)
Melting point: 192.0 ° C.

[Manufacturing of hook-and-loop fasteners]
Using the above warp yarns, weft yarns and monofilament yarns for the hook-shaped engaging elements, a plain weave was used as the weave structure, and the weave density after heat shrinkage was 55 warp yarns/cm and 19 weft yarns/cm. The monofilament yarns for the hook-shaped engaging elements were woven parallel to the warp yarns at a ratio of 1 for every 4 warp yarns, and loops were formed on the base fabric so that after 5 weft yarns had risen and fallen, they crossed over 3 warp yarns and formed loops at the crossing points.
In addition, when forming the loop for the hook-shaped engagement element, a method was used in which multiple metal rods were placed side by side on the woven base fabric parallel to the warp thread at the position where the yarn for the hook-shaped engagement element crosses the warp thread, the yarn for the engagement element was passed over the top of the metal rods to form a loop, and after the loop was formed, the metal rods were pulled out of the loop.

The fabric tape for hook fastener woven under the above conditions was run between the cooling roll (R ₁ ) and the press roll (R ₂ ) as shown in FIG. 3. On the other hand, the above-mentioned PET resin as the resin constituting the binder layer was heated and melted to 205°C and extruded from the T-die (T) in a layer (molten resin layer (6)). While the resin was kept in a molten state at 205°C, the molten resin layer (6) was pressed onto the second surface side of the loop fabric tape for hook-and-loop fastener (10) running between the cooling roll (R ₁ ) and the press roll (R ₂ ) to integrate the two. At that time, needle-like projections were provided on the surface of the cooling roll at a density of 18.5 pieces/cm 2 so that holes (7) with a diameter of 50 to 500 μm were formed penetrating from the back surface to the front ^surface of the resin layer (6). The thickness of the resin layer (6) was 50 μm and the basis weight was 63 g/m ² .
The thickness of the resin layer (6) is an average value obtained by averaging the dimensional measurement results of 30 points on the cross section of the resin layer using a measuring microscope such as a digital microscope, and was measured in the same manner as described below.

The integrated product of the two was then run along the roll surface of a cooling roll ( _R1 ) while the resin layer (6) was cooled and solidified, and the fabric tape for hook surface fasteners having the binder layer (6) integrated onto the second surface of the base fabric was peeled off from the surface of the cooling roll (R1) by running it along the surface of a sweeper roll (R4).
The obtained woven fabric tape for hook-and-loop fastener with the integrated binder layer was then placed in a heating zone at 210°C for 60 seconds to fix the loop shape of the loop for hook-like engaging element present on the first surface of the base fabric. It was then cooled, and one leg of the loop for hook-like engaging element was cut off using a cutting device having a structure in which cutting is performed by reciprocating a movable cutting blade between two fixed blades, to form a hook-like engaging element. The steps from weaving the fabric to integrating the binder layer with the second surface of the base fabric and further cutting off the one leg were carried out continuously without winding.

The density of the hook-like engaging elements of the obtained woven surface fastener having the hook-like engaging elements was 45 pieces/ ^cm2 , and the height of the hook-like engaging elements from the surface of the woven fabric base was 1.5 mm. Detailed observation of this hook-like engaging fastener under a microscope revealed that a part of the resin of the layer integrated with the second surface side of the base fabric had penetrated into the base fabric, but the weave was blocked by thermal shrinkage of the yarn constituting the woven fabric, and therefore the resin had not seeped out to the first surface side of the base fabric.
Furthermore, by cutting the hook-and-loop fastener parallel to the warp threads and parallel to the weft threads, it was confirmed that at the points on the first surface side of the base fabric where the warp threads and the threads for the engaging elements cross the weft threads, the warp threads and the threads for the engaging elements are not adhered to the weft threads by the PET-based resin integrated into the second surface of the base fabric.
At the same time, in the portion where the yarn for the engaging element is under the weft yarn on the second surface side of the base fabric, the yarn for the engaging element is bonded to the layer by the resin constituting the layer present on the second surface side of the base fabric. The pull-out force of the hook-shaped engaging element of this hook surface fastener was measured and found to be 10.01 N/piece, indicating excellent pull-out resistance.

The surface feel of this hook and loop fastener was also observed. Specifically, 13 people involved in the manufacture and research of hook and loop fasteners were asked to touch the surfaces of a commercially available PET-based woven hook and loop fastener in which the engaging elements are fixed by thermal fusion of the weft threads (A8693R.00 manufactured by Kuraray Fastening Co., Ltd.) and the hook and loop fastener obtained by this example, and asked which hook and loop fastener felt gentler to the touch. All 13 people answered that the hook and loop fastener of this example felt better to the touch. Most of the 13 people evaluated that the hook and loop fastener of this example felt soft and gentle to the touch, unlike conventional hook and loop fasteners, despite being a PET-based hook and loop fastener, which is said to be inferior in terms of flexibility. Note that the surface feel was evaluated in comparison with the comparative hook and loop fastener in terms of whether the engaging elements felt gentle on the skin and did not prick the skin.

In addition, regarding the overall hardness of the hook-and-loop fastener, if the base fabric part of the hook-and-loop fastener is stiff and difficult to grip when it is grasped as a whole, it is judged to be hard overall, i.e., inflexible, and if the base fabric part is soft and easy to grip, it is judged to be flexible, and the evaluation was made in comparison with the comparative hook-and-loop fastener.

Furthermore, when the engagement strength of this hook surface fastener was measured, the initial engagement strength was a shear strength of 14.9 N/ ^cm2 and a peel strength of 1.32 N/cm, and the engagement strength after 1000 engagements and peels was a shear strength of 14.3 N/ ^cm2 and a peel strength of 1.28 N/cm. Even after 1000 repeated engagements and peels, almost no hook-shaped engagement elements were found to have been pulled out from the surface of the hook surface fastener, demonstrating that this is an excellent hook surface fastener.

Furthermore, when this hook fastener was dyed with a disperse dye at 130°C for 1 hour, a hook fastener dyed a deep crimson color was obtained. When the hook fastener was cut across the warp and weft threads, each cross section was uniformly dyed a deep color from the back to the front of the hook fastener, that is, the binder layer, base fabric, and engaging elements of the hook fastener.

Examples 2 to 5, Comparative Example 1
A hook surface fastener was produced in the same manner as in Example 1, except that the multifilament yarns used for the warp and weft were changed to the following multifilament yarns. Then, a dyeing process was also carried out.
[Warp yarns used in Example 2]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: 1.1 mol% IPA and 2.2 mol% DEG)
Melting point: 255.8°C
Total decitex and number of filaments: 167 dtex, 30 filaments. Dry heat shrinkage at 200°C: 21.6%.
[Weft yarn used in Example 2]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: 1.1 mol% IPA and 2.2 mol% DEG)
Melting point: 255.2°C
Total decitex and number of filaments: 198 dtex, 48 filaments. Dry heat shrinkage at 200°C: 21.8%.

[Warp yarns used in Example 3]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 2.2 mol% and DEG 2.1 mol%)
Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 252.9°C
・200℃ dry heat shrinkage rate: 24.0%
[Weft yarn used in Example 3]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 2.2 mol% and DEG 2.1 mol%)
Melting point: 252.3°C
Total decitex and number of filaments: 198 dtex, 48 filaments. Dry heat shrinkage at 200°C: 24.2%.

[Warp yarns used in Example 4]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: 0.7 mol% IPA and 1.5 mol% DEG)
Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 258.4°C
・200℃ dry heat shrinkage rate: 20.6%
[Weft yarn used in Example 4]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: 0.7 mol% IPA and 1.5 mol% DEG)
Melting point: 257.8°C
Total decitex and number of filaments: 198 dtex, 48 filaments. Dry heat shrinkage at 200°C: 20.8%.

[Warp yarn used in Comparative Example 1]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 4.5 mol% and DEG 4.1 mol%)
Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 247.8°C
・200℃ dry heat shrinkage rate: 30.2%
[Weft yarn used in Comparative Example 1]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 4.5 mol% and DEG 4.1 mol%)
Melting point: 247.2°C
Total decitex and number of filaments: 198 dtex, 48 filaments. Dry heat shrinkage at 200°C: 30.4%.

[Warp yarns used in Example 5]
- Multifilament yarn made of pure PET (copolymerization ratio: IPA 0 mol%, DEG 1.4 mol%)
Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 261.3°C
・200℃ dry heat shrinkage rate: 18.9%
[Weft yarn used in Example 5]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: 0.0 mol% IPA and 1.4 mol% DEG)
Melting point: 260.7°C
Total decitex and number of filaments: 198 dtex, 48 filaments 200°C dry heat shrinkage: 19.1%

In the hook fastener of Comparative Example 1, since it was found that the single thread breakage and fuzz frequently occurred in the weaving process and thus a commercially valuable hook fastener could not be obtained, no further processes were carried out. All of the hook fasteners obtained in the above Examples except for Comparative Example 1 had a hook-like engaging element density of 45 pieces/ ^cm2 and furthermore, the height of the hook-like engaging elements from the surface of the woven fabric base was 1.5 mm.

These hook-and-loop fasteners were then examined under a microscope to see cross sections cut parallel to the warp threads and cross sections cut parallel to the weft threads. It was found that in all cases, the weave of the hook-and-loop fasteners was blocked due to thermal shrinkage of the threads making up the woven fabric, causing some of the resin of the layer integrated with the second surface of the base fabric to penetrate into the base fabric, but that the resin had not seeped out to the first surface of the base fabric.
Furthermore, it was confirmed that where the warp yarns and the yarns for the engaging elements cross the weft yarns on the first surface side of the base fabric, the warp yarns and the yarns for the engaging elements are not bonded to the weft yarns by the PET resin integrated with the second surface side of the base fabric, and where the yarns for the engaging elements slip under the weft yarns on the second surface side of the base fabric, the yarns for the engaging elements are bonded to the same layer by the resin constituting the layer present on the second surface side of the base fabric.

The performance of these hook-and-loop fasteners was measured. As a result, the pull-out strength of the hook-shaped engaging elements was 9.98 N/piece for Example 2, 10.22 N/piece for Example 3, 7.00 N/piece for Example 4, and 6.70 N/piece for Example 5. Although Examples 4 and 5 were inferior to Examples 2 and 3, all had practical pull-out strength. In addition, the feel of the surface of the hook-and-loop fasteners for Examples 2 and 3 was soft, similar to that of Example 1, but for Examples 4 and 5, all of the evaluators answered that although the overall hardness was flexible, the feel of the surface where the engaging elements were present was considerably harder than that of Example 1.

In terms of the engagement force, the hook-and-loop fasteners of Examples 4 and 5 both had inferior engagement force after 1,000 repeated engagement and peeling cycles, and had almost the same engagement force as that of Example 1, except that the hook-shaped engagement elements were observed to be pulled out from the surface of the hook-and-loop fastener after 1,000 repeated engagement and peeling cycles.
Furthermore, when the dyed hook-and-loop fastener was cut across the warp and weft threads, the cross sections were uniformly dyed from the second surface to the first surface in both Examples 2 and 3. However, for the hook-and-loop fasteners of Examples 4 and 5, a difference in density was observed between the base fabric and the resin layer on the second surface, giving the impression that something of a different color was integrated into the second surface side of the base fabric.

From the above results, it can be seen that the hook surface fasteners using the multifilament yarns made of copolymerized PET, in which IPA is copolymerized and whose melting point is within the range of 250 to 257°C, as the warp and weft yarns, as in Examples 1 to 3, have excellent surface feel and pull-out resistance of the engaging elements, excellent dyeability, and excellent engaging force. Moreover, in Examples 4 and 5, there is no problem with the initial engaging force, and all of the components are formed of polyester-based resin, making it possible to obtain a hook-and-loop fastener with excellent recyclability. However, it can be seen that the surface feel is inferior, and the pull-out resistance of the engaging elements, uniform dark color dyeability, and engaging force are also inferior. In Comparative Example 1, as described above, single thread breakage and fuzz generation occurred during the weaving process, and a hook-and-loop fastener could not be formed.
These results are shown in the following table. In the tables, the arrows indicate the same descriptions as the arrows indicate, and this is common to all tables.

Examples 6 to 7, Comparative Examples 2 to 3
In Example 1, the following four types of IPA copolymerized PET were prepared as the PET resin to be integrated on the second surface side of the woven fabric tape for hook surface fastener, and these four types of PET resins were used to produce four types of binder layer-integrated hook surface fasteners in the same manner as in Example 1. The resin temperatures used when integrating with the second surface of the woven fabric for hook surface fastener were 15° C. higher than the respective melting points.
[Example 6] PET copolymerized with 16 mol% IPA (melting point: 198.4°C)
[Example 7] PET copolymerized with 23 mol% IPA (melting point: 171.7°C)
[Comparative Example 2] IPA 28 mol% copolymerized PET (melting point: 155.0°C)
[Comparative Example 3] IPA 10 mol% copolymerized PET (melting point: 220.6°C)

In addition, when the binder layer was integrated onto the second surface of the base fabric in the hook fastener of Comparative Example 3, many of the loops for the engaging elements on the first surface of the base fabric collapsed and peeled off from the cooling roll, and did not stand up even after heat treatment to fix the hook shape was performed. It was therefore found that a commercially valuable hook fastener was not obtained, and therefore no further steps were performed.
The three types of hook fasteners obtained from the above Examples and Comparative Examples, excluding Comparative Example 3, all had a hook-like engaging element density of 45 pieces/ ^cm2 , and the height of the hook-like engaging elements from the surface of the woven base fabric was 1.5 mm. When these three types of hook-and-loop fasteners were observed under a microscope, and further cross sections cut parallel to the warp and cross sections cut parallel to the weft, it was confirmed that in all of the hook-and-loop fasteners, a part of the resin of the layer integrated with the second surface side of the base fabric penetrated into the base fabric, but the weave was blocked by thermal contraction of the threads constituting the woven fabric, and therefore the resin did not seep out to the first surface side of the base fabric, and as a result, it was confirmed that at the points where the warp and engaging element threads cross the weft on the first surface side of the base fabric, the warp and engaging element threads were not bonded to the weft by the PET-based resin integrated with the second surface of the base fabric. It was also confirmed that at the point where the yarn for the engaging element is slipped under the weft yarn on the second surface side of the base fabric, the yarn for the engaging element is adhered to the layer by the resin that constitutes the layer present on the second surface side of the base fabric.

The performance of these three types of hook surface fasteners was measured. As a result, the pull-out strength of the hook-shaped engaging elements was 9.98 N/piece for Example 6, 9.85 N/piece for Example 7, and 9.70 N/piece for Comparative Example 2, all of which were excellent values. However, the hook surface fastener of Comparative Example 2 had a part of the binder layer on the second surface side of the base fabric melted by ironing during the finishing process of the textile product, and as a result, the pull-out strength of the hook engaging elements decreased to 3.20 N/piece, making it unsuitable for use in textile products involving finishing processes.
As for the feel of the surface of the hook surface fastener, Examples 6 and 7, as well as Comparative Example 2, all had a soft feel similar to that of Example 1. As for the engaging force, all of the hook surface fasteners had an excellent engaging force almost equivalent to that of Example 1.
Furthermore, these three types of hook surface fasteners were subjected to high-pressure dyeing using the same disperse dye as in Example 1, and as a result, dyed surface fasteners were obtained in which the second surface of the base fabric was dyed a deep color and the cross section was uniformly dyed, just like in Example 1.

Example 8
The following yarn was prepared as a multifilament yarn for a loop-shaped engaging element, and a loop hook-and-loop fastener was produced by the following method using this multifilament yarn for the loop-shaped engaging element, the warp multifilament yarn described in Example 1, and the weft multifilament yarn described in Example 1, and further using the PET-based resin integrated onto the second surface of the base fabric described in Example 1.
[Multifilament yarn for loop-shaped engagement element]
・Multifilament yarn made of copolymerized PET (copolymerization ratio: IPA 2.2 mol% and DEG 2.1 mol%)
Total decitex and number of filaments: 289 dtex, 8 filaments Melting point: 253.6°C
・200℃ dry heat shrinkage rate: 23.2%

[Manufacturing of loop fasteners]
Using the above warp yarns, weft yarns and multifilament yarns for loop-shaped engaging elements, a plain weave was used as the weaving structure, and the weaving density (after heat shrinkage treatment) was 55 warp yarns/cm and 21 weft yarns/cm. The multifilament yarns for loop-shaped engaging elements were woven parallel to the warp yarns without crossing them at a ratio of 1 for every 4 warp yarns, and after the 5 weft yarns were allowed to float and sink, loops were formed on the woven base fabric.
The loop fastener tape woven under the above conditions was treated in the same manner as in Example 1 to manufacture a woven fabric tape for loop fasteners by integrating a binder layer onto the second surface of the base fabric, and then the multifilament yarns constituting the loops were loosened by rubbing the surface of the fastener having the loop-shaped engaging elements with a card cloth or the like. Note that the process from weaving the fabric to the process of integrating the binder layer onto the second surface was carried out continuously without winding. Furthermore, high-pressure dyeing with disperse dyes was carried out in the same manner as in Example 1.

The density of the loop-shaped engaging elements of the obtained woven fabric for loop hook-and-loop fastener was 44 pieces/ ^cm2 , and the height of the loop-shaped engaging elements from the surface of the woven fabric base was 2.1 mm. When the cross section of the loop hook-and-loop fastener cut parallel to the warp and the cross section of the loop hook-and-loop fastener cut parallel to the weft were observed under a microscope, it was found that a part of the resin of the layer integrated with the second surface side of the base fabric had penetrated into the base fabric, but the weave was blocked by the thermal contraction of the threads constituting the woven fabric, and therefore the resin did not seep out to the first surface side of the base fabric. As a result, it was confirmed that the warp and the threads for the engaging elements were not bonded to the weft by the PET resin integrated with the second surface of the base fabric at the places where the threads for the engaging elements straddled the weft on the first surface side of the base fabric. It was also confirmed that the threads for the engaging elements were bonded to the layer by the resin constituting the layer present on the second surface side of the base fabric at the places where the threads for the engaging elements slipped under the weft on the second surface side of the base fabric.

The feel of the surface of the obtained loop hook-and-loop fastener was observed in the same manner as in Example 1. Loop hook-and-loop fasteners are generally flexible and have a much softer and superior feel to the touch than hook-and-loop fasteners, but all of the evaluators answered that the loop hook-and-loop fastener of this example was even better in feel than a commercially available PET-based woven hook-and-loop fastener in which loop-shaped engaging elements are fixed by thermal fusion of the weft threads (B2790R.00, manufactured by Kuraray Fastening Co., Ltd.).

The pull-out force of the loop-shaped engaging element of this loop hook-and-loop fastener was measured to be 16.21 N, demonstrating excellent pull-out properties. As mentioned above, the pull-out properties of the loop-shaped engaging element were measured in a state where the multifilament yarn forming the loop-shaped engaging element was cut at the point where the multifilament yarn forming the loop-shaped engaging element formed a loop, sunk under the weft yarn, and then rose to the first surface of the base fabric.

Furthermore, when the engagement strength of this loop surface fastener was measured, the initial engagement strength was 14.8 N/ ^cm2 in shear strength and 1.50 N/cm in peel strength, and the engagement strength after 1000 engagements and peels was 14.4 N/ ^cm2 in shear strength and 1.44 N/cm in peel strength, which are satisfactory values in terms of engagement strength, and no loop-shaped engagement elements were found to have been pulled out from the surface of the loop surface fastener even after 1000 repeated engagements and peels.

Furthermore, when this loop hook-and-loop fastener was subjected to a high-pressure dyeing process using a disperse dye, it was dyed a vivid deep crimson color, exhibiting excellent dyeability, and when this dyed loop hook-and-loop fastener was cut, the cross section was uniformly dyed a deep color from the front to the back of the loop hook-and-loop fastener, that is, the binder layer, base fabric, and engaging elements of the hook-and-loop fastener.

Example 9
A hook-and-loop coexisting surface fastener was produced by the following method using the warp yarn, weft yarn, and monofilament yarn for hook-shaped engaging element described in Example 1 above, and the multifilament yarn for loop-shaped engaging element described in Example 8, and further using a PET-based resin integrated onto the second surface of the base fabric in the same manner as in Example 1.

[Preparation of hook-and-loop type hook-and-loop fastener]
A plain weave was used as the weave structure, with a weave density (after heat shrinkage treatment) of 55 warp threads/cm and 18.5 weft threads/cm. A multifilament thread for a loop-shaped engagement element or a monofilament thread for a hook-shaped engagement element was used in a ratio of 1 for every 4 warp threads. In the case of a multifilament thread for a loop-shaped engagement element, three weft threads were raised and lowered, then one warp thread was crossed and woven in parallel to the warp threads to form a loop at the point where one warp thread was crossed. In the case of a monofilament thread for a hook-shaped engagement element, three weft threads were raised and lowered, then three warp threads were crossed and a loop was formed on the base fabric at the point where the weft threads were crossed.

In this case, the multifilament yarn for the loop-shaped engagement element and the monofilament yarn for the hook-shaped engagement element were woven alternately so that each yarn was present in a continuous pair of two. When forming the loop for the hook-shaped engagement element, similar to the above-mentioned Example 1, multiple metal rods were placed on the woven base fabric parallel to the warp yarn at a position where the yarn for the hook-shaped engagement element straddles the warp yarn, and the yarn for the engagement element was passed over the top of the metal rods to form a loop, and after the loop was formed, the metal rod was pulled out of the loop.

The woven hook-and-loop coexisting type hook-and-loop fastener tape was processed in the same manner as in Example 1 to manufacture a woven hook-and-loop fastener tape by integrating a binder layer onto the second surface of the base fabric, and then the same heat treatment as in Example 1 was carried out to fix the shape of the hook-shaped engaging elements. Then, the process of cutting one leg of the loop for the hook-shaped engaging elements was carried out in the same manner as in Example 1, and the surface of the loop-shaped engaging elements was rubbed with card clothing to loosen the multifilament yarn forming the loop of the loop-shaped engaging elements. The process from weaving the fabric to the process of cutting one leg of the loop for the engaging elements and then loosening the loop-shaped engaging elements with card clothing were carried out continuously without winding up in between. Furthermore, high-pressure dyeing with disperse dyes was carried out in the same manner as in Example 1.

The density of the hook-like engaging elements of the obtained hook-loop coexisting type surface fastener was 32/ ^cm2 , the density of the loop-like engaging elements was 32/ ^cm2 , the height of the hook-like engaging elements from the surface of the base fabric was 1.7 mm, and the height of the loop-like engaging elements from the surface of the base fabric was 2.1 mm. When the cross section cut parallel to the warp yarn and the cross section cut parallel to the weft yarn of this hook-loop coexisting type surface fastener were observed under a microscope, it was found that a part of the resin of the layer integrated with the second surface side of the base fabric had penetrated into the base fabric, but the weave was blocked by thermal contraction of the yarn constituting the woven fabric, so that the resin did not seep out to the first surface side of the base fabric, and as a result, it was confirmed that the warp yarn and the engaging element yarn were not bonded to the weft yarn by the PET resin integrated with the second surface of the base fabric at the portion where the warp yarn and the engaging element yarn cross the weft yarn on the first surface side of the base fabric. Furthermore, at the points where the yarn for the engaging element is slipped under the weft yarn on the second surface side of the base fabric, it was observed that the yarn for the engaging element is adhered to the layer by the resin that constitutes the layer present on the second surface side of the base fabric.

The feel of the surface of the hook-and-loop coexisting type surface fastener thus obtained was observed in the same manner as in Example 1, and all of the evaluators answered that the hook-and-loop coexisting type surface fastener of this Example was much softer and superior in feel to the touch than a commercially available PET-based woven surface fastener in which both loop-shaped engaging elements and hook-shaped engaging elements coexist on the first surface and these engaging elements are fixed by thermal fusion of the weft yarns (F9820Y.00 manufactured by Kuraray Fastening Co., Ltd.).The overall hardness was also evaluated as being flexible.

The pull-out force of the hook-shaped engaging elements of this surface fastener was measured and found to be 7.61 N/element, demonstrating that this hook-and-loop type surface fastener has excellent pull-out resistance.
Furthermore, when the engagement strength of this hook-and-loop parallel type surface fastener was measured, the initial engagement strength was 10.3 N/ ^cm2 in shear strength and 1.42 N/cm in peel strength, and the engagement strength after 1000 engagements and peels was 9.0 N/ ^cm2 in shear strength and 1.29 N/cm in peel strength, demonstrating that it has excellent engagement strength for a hook-and-loop parallel type surface fastener, and even after 1000 repeated engagements and peels, no hook-shaped engagement elements or loop-shaped engagement elements were found to have been pulled out of the woven base fabric.

When this hook-and-loop coexisting type hook-and-loop fastener was dyed with a crimson disperse dye in the same manner as in the Example, a vivid hook-and-loop fastener was obtained that was uniformly dyed a deep crimson color, and it was found to have extremely excellent dyeability. Furthermore, when the dyed hook-and-loop fastener was cut and the cross section was observed, it was found that the hook-and-loop fastener's binder layer, base fabric, and engaging elements were all uniformly dyed a deep color from the top to the bottom of the cross section. Furthermore, even when the surface of the hook-shaped engaging elements was lightly rubbed with a sandpaper, the undyed inner layer was not exposed.

Comparative Example 4
In the above Example 1, the PET-based multifilament yarn used as the weft yarn was replaced with a multifilament yarn made of the core-sheath type composite filament described below, and a method was used in which a layer made of PET-based resin was integrated onto the second surface of the loop fabric. A hook surface fastener was then produced by heat treating the multifilament yarn for 60 seconds at 210°C, the temperature at which the sheath component of the multifilament yarn made of the core-sheath type composite filament used for the weft yarn melts, thereby melting the sheath component of the weft yarn and adhering and fixing the warp yarn and the yarn for the engaging element.

[Weft yarn: multifilament yarn made of core-sheath type composite filaments]
Core component: non-copolymerized PET
Sheath component: PET copolymerized with 25 mol% isophthalic acid (softening point: 190.0°C)
Core/sheath ratio (weight ratio): 70:30
Total decitex and filament count: 198 dtex, 48 filaments Dry heat shrinkage at 200°C: 16.2%

The hook hook fastener obtained was cut parallel to the weft to observe the state of adhesion between the warp and engaging element threads and the weft. As a result, it was confirmed that at the points where the warp and engaging element threads cross the weft on the first surface side of the base fabric, the warp and engaging element threads are completely adhered to the weft by the sheath component of the weft. As a result, there were no problems with the pull-out resistance of the hook-shaped engaging elements, but in regard to the feel of the surface of this hook hook fastener, the results of an evaluation by 13 evaluators in the same manner as in Example 1, all 13 evaluators rated the hook hook fastener of this comparative example as being harder than that of Example 1 and inferior in terms of feel and flexibility.

Comparative Example 5
In the above Example 1, the PET-based multifilament yarn used as the warp yarn, the multifilament yarn used as the weft yarn, and the monofilament yarn used for the engaging element yarn were changed to the yarns shown below, the warp yarns and the weft yarns were woven at a weave density of 55 threads/cm for the warp yarn and 19 threads/cm for the weft yarn, and the weight of the binder layer integrated onto the second surface of the loop fabric was changed to 120 g/ ^m2 , which is approximately twice that of Example 1. A hook surface fastener was manufactured in the same manner as in Example 1, except for this.

[Warp threads]
Multifilament yarn made of PET (non-copolymerized) Total decitex and number of filaments: 167 dtex, 30 filaments Melting point: 261.0°C
・200℃ dry heat shrinkage rate: 18.8%
[Weft thread]
Multifilament yarn made of PET (non-copolymerized) Total decitex and number of filaments: 198 dtex, 48 filaments Melting point: 261.0°C
・200℃ dry heat shrinkage rate: 19.0%
[Monofilament yarn for hook-shaped engaging element]
Monofilament thread made of PET (non-copolymerized) Diameter: 0.23 mm
Melting point: 261.4°C
・200℃ dry heat shrinkage rate: 18.0%

The obtained hook hook fastener was rigid, and by cutting this hook fastener parallel to the weft, the adhesion state of the warp threads and the threads for the engaging elements to the weft threads and the penetration state of the binder layer integrated on the second surface side into the base fabric were observed. As a result, it was confirmed that the PET-based resin integrated on the second surface side of the base fabric had permeated the weave of the base fabric and flowed out to the first surface of the base fabric, and that the warp threads and the threads for the engaging elements were completely adhered to the weft threads at the points where they crossed the weft threads on the first surface side of the base fabric. The feel of the surface of this hook hook fastener was evaluated in the same manner as in Example 1, and all 13 evaluators evaluated that the hook hook fastener of this comparative example was much harder than that of Example 1, and was significantly inferior in terms of feel and flexibility.

As stated above, a preferred embodiment of the present invention has been described with reference to the drawings. However, a person skilled in the art would easily imagine various changes and modifications within the obvious scope upon reading this specification. Therefore, such changes and modifications are to be interpreted as being within the scope of the invention as determined by the scope of the claims.

1: Weft thread 2: Warp thread 3: Hook-shaped engaging element 4: Loop-shaped engaging element 5: Woven fabric 6: Layer made of resin (A) 7: Hole provided in layer made of resin (A) 8: Depression 9: Area where engaging element thread is slipped under weft thread 10: Loop fabric for hook-and-loop fastener T: T-die R1: Cooling roll R2: Press roll R3: Backup roll R4: Sweeper roll

Claims

A woven fabric surface fastener having a base fabric woven with warp yarns, weft yarns and threads for engaging elements, a first surface of the base fabric being the front side and a second surface being the back side, the threads for engaging elements being woven into the base fabric parallel to the warp yarns, and a number of hook-shaped and/or loop-shaped engaging elements formed from the threads for engaging elements and rising from the first surface of the base fabric are present on the first surface of the base fabric, and the warp yarns, weft yarns and threads for engaging elements are all constituted by threads made of a polyethylene terephthalate-based resin, comprising the following configurations 1) and 2):
1) A binder layer made of a polyethylene terephthalate resin having a melting point of 160 to 210°C and copolymerized with isophthalic acid is provided on the second surface of the base fabric, and the engaging element thread is directly bonded and fixed by the resin of the binder layer;
and 2) the first surface of the base is free of the resin of the binder layer;
This is a polyethylene terephthalate-based woven hook-and-loop fastener that satisfies both of these requirements.
A woven fabric surface fastener having a base fabric woven with warp yarns, weft yarns and threads for engaging elements, a first surface of the base fabric being the front side and a second surface being the back side, the threads for engaging elements being woven into the base fabric parallel to the warp yarns, and a number of hook-shaped and/or loop-shaped engaging elements formed from the threads for engaging elements and rising from the first surface of the base fabric are present on the first surface of the base fabric, and the warp yarns, weft yarns and threads for engaging elements are all constituted by threads made of a polyethylene terephthalate-based resin, comprising the following configurations 1) and 2):
1) a binder layer made of a polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C is provided on the second surface of the base fabric, a part of the resin of the binder layer penetrates into the inside of the base fabric, and the engaging element yarn is bonded almost entirely by the resin constituting the binder layer at a portion on the second surface of the base fabric where the engaging element yarn is embedded under the weft yarn; and 2) the warp yarn and the engaging element yarn are not bonded to the weft yarn at a portion on the first surface of the base fabric where the warp yarn and the engaging element yarn cross the weft yarn.
This is a polyethylene terephthalate-based woven hook-and-loop fastener that satisfies both of these requirements.
The polyethylene terephthalate-based woven hook-and-loop fastener according to claim 1 or 2, wherein at least one of the warp threads and weft threads is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 257°C.
The polyethylene terephthalate-based woven hook-and-loop fastener according to claim 1 or 2, wherein the thread for the engaging element is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 265°C.
The polyethylene terephthalate-based woven hook-and-loop fastener according to claim 1 or 2, wherein the warp threads, weft threads and threads for the engaging elements are all made of a copolymerized polyethylene terephthalate resin containing, as copolymerization components, 1.0 to 2.0 mol % of isophthalic acid based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % of diethylene glycol based on the total amount of diols.
The polyethylene terephthalate-based woven fabric hook-and-loop fastener according to claim 1 or 2, wherein the binder layer bonded to the second surface of the base fabric has a large number of holes penetrating the layer in the thickness direction.
A textile product with a polyethylene terephthalate-based woven hook-and-loop fastener, in which the polyethylene terephthalate-based woven hook-and-loop fastener according to claim 3 is attached to a textile product made of a polyethylene terephthalate-based resin and dyed the same color as the textile product with the same disperse dye.
A method for producing a woven fabric surface fastener using a woven fabric as a base fabric, the woven fabric being composed of warp yarns made of polyethylene terephthalate resin copolymerized with isophthalic acid and weft yarns and yarns for engaging elements made of polyethylene terephthalate resin, a first surface of the base fabric being the front side and a second surface being the back side, the yarns for engaging elements being woven into the base fabric parallel to the warp yarns, the first surface of the base fabric having a number of hook-shaped and/or loop-shaped engaging elements formed from the yarns for engaging elements and rising from the surface of the base fabric, and the second surface of the base fabric having a binder layer made of polyethylene terephthalate resin copolymerized with isophthalic acid and having a melting point of 160 to 210°C, characterized in that the following steps A, B and C are carried out in this order.
[Step A] A step of weaving a loop fabric by weaving threads for engaging elements parallel to the warp threads and simultaneously causing the threads for engaging elements to rise in regular loops from the first surface of the base fabric at the locations where the threads cross the weft threads,
[Step B] A step of attaching the resin for the binder layer to the second surface of the base fabric and adhering and fixing the yarn for the engaging element with the resin of the binder layer;
[Step C] When the loop is made of monofilament yarn, a step of heating the first surface side of the loop fabric to fix the loop shape, followed by cooling, and cutting one leg of the loop to make the loop into a hook-shaped engaging element.
The method for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to claim 8, wherein the [Step B] is a step of attaching the resin for the binder layer in a molten state as a film-like substance to the second surface of the loop fabric, directly pressing the resin and densifying the loop fabric, causing a portion of the film-like substance to penetrate into the interior of the second surface of the base fabric, and then cooling and solidifying the molten resin to bond it to the thread for the engaging elements.
The method for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to claim 8 or 9, wherein the film-like material made of the resin for the binder layer is obtained by heating and melting a fiber sheet.
The method for manufacturing a polyethylene terephthalate-based woven surface fastener according to claim 8 or 9, wherein at least one type of thread selected from the group consisting of the warp threads, weft threads, and threads for engaging elements is a thread made of a polyethylene terephthalate-based resin copolymerized with isophthalic acid and having a melting point of 250 to 265°C.
The method for manufacturing a polyethylene terephthalate-based woven surface fastener according to claim 8 or 9, wherein the warp threads, weft threads and threads for the engaging elements are all threads made of copolymerized polyethylene terephthalate resin containing 1.0 to 2.0 mol % of isophthalic acid based on the total amount of dicarboxylic acids and 2.0 to 3.5 mol % of diethylene glycol based on the total amount of diols as copolymerization components.
The method for manufacturing a polyethylene terephthalate-based woven surface fastener according to claim 8 or 9, wherein the dry heat shrinkage rate at 200°C of the yarns made of polyethylene terephthalate-based resin used as the warp yarns, weft yarns, and threads for the engaging elements is in the range of 10 to 35%.
The method for producing a polyethylene terephthalate-based woven fabric hook-and-loop fastener according to claim 8 or 9, in which through holes are formed in the binder resin layer.
A method for manufacturing a textile product with a polyethylene terephthalate-based woven hook-and-loop fastener, comprising attaching the polyethylene terephthalate-based woven hook-and-loop fastener according to claim 3 to a textile product made of polyethylene terephthalate-based resin and simultaneously dyeing the textile product in the attached state to the same color using a disperse dye.