CN1914369A - Plush fabric and method for production thereof - Google Patents

Abstract

The invention provides a plush fabric which comprises a base structure portion having a knitted or fabricated structure comprising organic fiber yarns, and a plush portion comprising polyester based fibers, characterized in that in one or more partial regions of the plush portion, the plush portion has the height being gradually reduced, to thereby form a slope portion having an inclination angle of 0.5 to 10 degrees.

Description

Pile fabric and its manufacturing method

technical field

The present invention relates to a pile fabric composed of a ground structure portion and a pile portion and a manufacturing method thereof. More specifically, it relates to a high-quality pile fabric having a gradually changing gradient portion on the surface of the pile portion and a method for manufacturing the same.

Background technique

Conventionally, pile fabrics have been used mainly in the fields of vehicle interior materials, interior materials, clothing materials, and the like. In recent years, among the pile fabrics, the pile fabric having a three-dimensional pattern on the surface of the fabric has attracted special attention as a high-quality pile fabric. As a method of forming this three-dimensional pattern, a method of physically forming unevenness and a method of chemically forming unevenness are known.

As a method of physically forming concavities and convexities, shaping (such as embossing, satin finishing, etc.) by contact pressure of an engraved roll under high temperature heating is known. However, in order to insert the fabric between heated rolls under heavy pressure, There are serious problems of hardening of the hand or flattening of the fabric, and there are problems of metallic luster and thermal discoloration by heat rollers.

Also, as a method of chemically forming concavities and convexities, such as: after printing with an alkaline agent such as sodium hydroxide, the method of dissolving the printed part to form a concavity and convexity difference (step-like step height difference) (such as: Patent Document 1) , using an inorganic or organic solvent as a fiber shrinking agent, spraying the fiber shrinking agent on the pile fabric, shrinking the pile yarn, and forming a method of high-contrast concave-convex pattern (such as: patent document 2). However, these step-like concave-convex height differences or pile fabrics with high-contrast concave-convex patterns cannot meet the requirements of a high-level sense. In addition, in the method of spraying the fiber shrinking agent on the pile fabric, the fiber shrinking agent is usually high viscosity, so there is a problem that the nozzle part is clogged or a special spraying device controlled by a computer must be used.

(Patent Document 1) Japanese Patent Publication No. 2-35075

(Patent Document 2) JP-A-10-298863

Contents of the invention

The object of the present invention is to provide a high-quality fleece fabric and its manufacturing method. This object can be achieved by the fleece fabric of the present invention and its manufacturing method.

The pile fabric of the present invention is a pile fabric composed of a ground structure portion having a knitted or woven structure comprising organic fiber yarns and a pile portion comprising polyester fibers, and is characterized in that in the pile portion In one or more local regions, the height of the pile head is gradually reduced, thereby forming a gradient portion at an inclination angle of 0.5 to 10 degrees.

Among them, it is preferable that the pile portion contains two or more types of pile yarns different in brightness or hue, or two or more types of pile yarns that differ in brightness and hue, and gradually change the color along the gradient of the gradient portion.

In addition, in the gradient portion, it is preferable that the depth difference between the maximum pile head height and the minimum pile head height is within the range of 0.6-1.0 mm.

And it is preferable to form a some gradient part in a pile part, and to provide a style by these some gradient part.

In the fleece fabric of the present invention, the number of fine recesses with an area of 0.05 mm ² or more is preferably 120 pieces/cm ² or less in the region of 40% of the maximum pile head height side of the gradient portion.

Furthermore, in the 40% region of the maximum pile head height side, it is preferable that the total area of the fine recesses with an area of 0.05 mm ² or more is 20% or less of the total area of the 40% region.

The fleece fabric of the present invention is preferably subjected to colored printing.

The pile fabric of the present invention is partially removed by chemical etching to have a pile portion of the pile fabric composed of a knitted or woven structure portion comprising organic fiber yarns and a pile portion comprising polyester fibers, By gradually reducing the height of the pile head, a gradient portion with an inclination angle of 0.5-10 degrees is formed, which can be produced by the method of making the pile fabric characterized by this.

In this case, two or more types of pile yarns having different pile yarn heights are contained in the pile head before partial removal by the chemical etching method, and these pile yarns are different in brightness or hue, or in brightness and hue Different from each other is preferred.

Also, when partially removing the pile portion by the chemical etching method, it is preferable to use a rotary screen having a portion having a portion in which the hole diameter of the etching treatment liquid discharge hole is gradually increased.

At this time, it is preferable to use 2-5 rotating nets, and perform chemical etching treatment by overlapping continuously.

Description of drawings

Fig. 1 is a schematic explanatory diagram showing an aspect of forming a gradient portion 1 in the pile portion of the pile fabric of the present invention.

Fig. 2 is a schematic explanatory view showing another aspect of the fleece fabric of the present invention.

Fig. 3 is a schematic explanatory view showing a method of forming non-gradient steps in the pile portion of a conventional pile fabric.

Fig. 4 is an explanatory view for explaining the pile head height L of the pile head in the pile fabric of the present invention.

Fig. 5 is an example of a pattern that can be formed by a plurality of gradient parts in the fleece fabric of the present invention.

Best form of invention practice

The pile fabric of the present invention is formed by (A) a ground structure part having a knitted or woven structure containing organic fiber yarns and (B) a pile part containing polyester fibers, and the pile part is machine-woven into Or knit into the ground weave, which is formed by a plurality of pile yarns (cut piles) extending from at least one side of the ground weave.

The pile head is composed of pile yarns containing polyester fibers. The pile yarn which comprises a pile part may be 1 type, and may be 2 or more types. Also, when there are two or more types of pile yarns, the height, brightness, and color of the pile yarns may be different from each other. The pile yarn may be a generally crimped pile yarn imparting curl, or may be a non-crimped pile yarn. Furthermore, the pile head can be formed by curled pile yarn and non-curled pile yarn. When the pile part contains a curly pile yarn, since the lodging resistance of a pile yarn improves, it is preferable. Also, examples of methods for imparting crimp include false twist crimping, air jet processing, and compression crimping.

The polyester resin forming the pile yarn is made of dicarboxylic acid components and diol components. It is preferable to mainly use terephthalic acid as the dicarboxylic acid component, and it is preferable to mainly use at least one alkylene glycol selected from ethylene glycol, propylene glycol, and butanediol as the diol component. In addition, the third component other than the dicarboxylic acid component and the diol component may be contained in the polyester resin. As the third component, one or more of the following substances can be used: cationic dye-dyeable anionic components, such as sodium sulfoisophthalic acid; dicarboxylic acids other than terephthalic acid, such as isophthalic acid and naphthalene dicarboxylic acid , adipic acid, sebacic acid; and diol compounds other than alkylene glycols, such as diethylene glycol, polyethylene glycol, bisphenol A, bisphenol sulfone.

In this polyester resin, if necessary, one or more matting agents (titanium dioxide), micropore forming agents (organic sulfonic acid metal salts), anti-coloring agents, heat stabilizers, and flame retardants (antimony trioxide) may be contained. , Fluorescent whitening agent, coloring pigment, antistatic agent (sulfonic acid metal salt), hygroscopic agent (polyoxyalkylene glycol), antibacterial agent, and other inorganic particles.

The single fiber fineness (count) of polyester fiber, or the total fineness (count) of the yarn for forming the pile head made of more than one kind is not limited. Generally, the single fiber fineness is 0.5-5dtex, and the pile head The total denier of the forming yarn is preferably 30-300 dtex. When the single fiber fineness is less than 0.1dtex, the lodging resistance will be insufficient, and the touch of the pile head will be too soft, on the contrary, if it exceeds 10dtex, the touch of the pile head will be too hard. When the total fineness of the pile forming yarn is less than 30 dtex, or exceeds 300 dtex, there will be a problem that the workability of the yarn during processing such as crimping or blending with other yarns, or during weaving or knitting will be reduced. . The cross-sectional shape of the single fiber is not limited, and in addition to the general circular cross-section, it can also be a triangular, flat, flattened, cross-shaped, hexagonal, or hollow cross-sectional shape. In addition, the yarn for forming the pile head can also be a composite yarn formed of two or more constituent yarns. In this case, the polyester resins constituting the yarns are different from each other, or they can be made into different colors or different colors by mixing a coloring agent. All dyeable.

In the pile fabric of the present invention, as shown schematically in FIG. 1 , the gradient portion 1 is formed by gradually decreasing the height L of the pile head in more than one local area of the pile head. The gradient portion is obtained by removing the end portion of the polyester pile yarn constituting the pile portion by chemical etching as will be described later. By forming a gradient part at the pile head, the height of the pile head is high, and the color is light; on the contrary, the height of the pile head is low, and the color becomes darker, and the gradient changes from light to dark along the gradient. Therefore, A sense of luxury can be obtained.

Wherein, the inclination angle A of the gradient portion must be in the range of 0.5-10 degrees (preferably 1-3 degrees). If the inclination angle A is an acute angle greater than 10 degrees, the luminance changes drastically when changing from a light color to a dark color, and thus a sufficient sense of luxury cannot be obtained. On the contrary, if the inclination angle is less than 0.5 degrees, the brightness cannot be changed sufficiently, and a sufficient sense of luxury cannot be obtained. Moreover, as shown schematically in FIG. 3 , when the unevenness with no gradient step height difference is formed on the pile head, the sense of luxury cannot be obtained, which is not ideal.

At this time, as shown schematically in FIG. 2, the pile head includes two or more kinds of pile yarns that are different in brightness or hue, or brightness and color, and the color gradually changes along the gradient to obtain a particularly excellent sense of luxury. , so it is preferred.

In addition, in the gradient portion, it is preferable that the depth difference H between the maximum pile head height and the minimum pile head height of the gradient portion is 0.6-1.0 mm to obtain a sufficient sense of luxury. In addition, it is preferable that the maximum pile head height L of the pile head is 1-5 mm (more preferably 1.5-3 mm), so that a sufficient sense of luxury can be obtained. In addition, when the pile yarn is inclined (less than 90 degrees) relative to the weave portion, the pile height L of the pile portion is a value when the vertical distance is measured as shown in FIG. 4 .

In this gradient portion, it is preferable that there are few fine irregularities on the surface (inclined surface) of the gradient portion. When the surface of the gradient part has few fine irregularities and is smooth, the lightness changes slowly when changing from light color (the side with the largest pile height) to dark color (the side with the smallest pile height) along the gradient, so that a sufficient sense of luxury can be obtained. As a criterion for the small number of fine concavities and convexities, the number of fine concavities with an area of 0.05 mm ² or more in the 40% region of the maximum height side of the gradient portion is 120 or less/cm ² (more preferably 10-100/cm ² ) is preferred. In particular, it is more ideal that the total area of the recesses is less than 20% (more preferably 2-10%) relative to the total area of the 40% region. Such a smooth gradient with few fine recesses can be obtained by successively repeating the etching process with a plurality of rotating screens as described later. In addition, the 40% region on the maximum height side of the gradient portion refers to the surface area of the gradient portion corresponding to a region of 0.4W in FIG. 1 .

In addition, it is more desirable to form gradient portions in a plurality of partial regions of the pile head, and to form a pattern through these gradient portions to increase the sense of luxury. As this pattern, the square as shown in Figure 5 (the length of each side is about 1-3cm is appropriate) is the examples such as the continuous pattern of plane, drop pattern, grid pattern, alternate checkered pattern. In addition, in Fig. 5, the pile head height in the light-colored part is high, while the pile head height in the dark-colored part is low.

The knitted or woven structure of the pile fabric of the present invention is not limited, for example, warp pile woven fabric, weft yarn pile woven fabric, sinking pile knitted fabric, Russell pile knitted fabric, warp knitted pile knitted fabric Cut pile fabric obtained by cutting such as loop pile.

In the pile fabric of the present invention, the yarn type, fiber type, monofilament fineness, and total fineness used in the ground weave portion are not particularly limited, and organic fiber yarns used in general pile fabrics can be used. Examples of the organic fiber yarn include cotton, wool, hemp, viscose, rayon fibers, polyester fibers, nylon fibers, polyolefin fibers, cellulose acetate fibers, and the like. Generally, the yarns for the ground structure of the pile fabric of the present invention are preferably selected from polyester multifilament yarns, thereby obtaining a ground structure with good touch and dyeability.

The distribution of pile yarns in the pile head of the pile fabric of the present invention is preferably in the range of 34000-220000 dtex/cm ² . If the pile yarn density is less than 34000 dtex/cm ² , the pile yarns in the pile head tend to fall down during the etching process, and the etching effect may become unstable. Conversely, if it exceeds 220,000 dtex/cm ² , during etching treatment, the permeability of the alkali treatment liquid to the pile head may be poor, and satisfactory etching treatment cannot be performed.

The pile fabric of this invention can be manufactured by the following method, for example.

First, after knitting or weaving a pile fabric having a ground structure part of a knitted or woven structure containing the above-mentioned organic fiber yarn and a pile head part containing the above-mentioned polyester fiber, it is cut by a general method. The loop pile of the fabric is made into pile fabric.

In this case, the pile yarns constituting the pile head may be one type, or two or more types of pile yarns having different pile yarn heights, and the brightness, hue, or brightness of these pile yarns may be different. It is preferred to be different from each other in terms of hue and hue. In this way, various pile yarns with different pile heights and colors are contained in the pile head, and when the gradient portion is formed, the color changes gradually along the gradient of the gradient portion, so that a particularly desirable sense of luxury can be obtained. For example, an uncolored (white) pile yarn with a high pile yarn height and a colored pile yarn with a low pile yarn height constitute a pile head, and a gradient portion is formed by etching, and the pile head The place with a high height is white, on the contrary, the place with a low pile head is colored, and the color changes slowly from white to colored along the gradient, so it can obtain a sense of luxury. Also, a pile yarn having a pile yarn height between a pile yarn with a high pile yarn height and a pile yarn with a low pile yarn height is contained, and at the same time, there is an intermediate pile yarn If the thread-height pile yarn is colored in another color, various color changes can be obtained, which can further enhance the sense of luxury.

Also, the method of making pile yarns with different heights, for example, when knitting or weaving pile fabrics, using two or more yarns with different boiling water shrinkage rates as yarns for pile yarns to form pile heads Thereafter, a method of performing heat treatment, or a method of forming a crimp after forming a pile head using a blended yarn in which a non-crimped yarn and a crimped yarn are simultaneously plied and blended as a pile yarn.

Then, after the pile head of the pile fabric is partially removed by chemical etching, the height of the pile head is gradually reduced to form a gradient portion with an inclination angle of 0.5-10 degrees, thereby making it easy to manufacture the pile fabric of the present invention .

Among them, when the pile portion is partially removed by chemical etching, it is preferable to use a rotating net having a portion in which the diameter of the discharge hole of the etching treatment liquid is gradually increased. A large number of etching liquid discharge holes are pierced on the surface of the rotating screen, and at least the diameter of the discharge holes has a gradually increasing portion. Since a large amount of etching treatment liquid is discharged from the discharge hole having a large diameter, the pile head is deeply etched, and the height of the pile head becomes low. Conversely, since a small amount of etching treatment liquid is discharged from the discharge hole having a small diameter, the pile portion is slightly etched. As a result, a gradient can be formed in one or more partial regions of the pile head.

In addition, when forming a pattern on the pile head by etching, it is necessary to arrange discharge holes in a pattern on the rotating net. For example, when forming a planar continuous pattern of squares as shown in FIG. 4 on the pile head, it is necessary to arrange the discharge holes in a corresponding pattern.

The number of the rotary nets is preferably 2-5. Using the second and subsequent rotary screens on the gradient formed by the first rotary screen, and further repeating the etching process, a smooth gradient with few fine irregularities as described above can be obtained. In addition, as the number of rotating nets, 5 are enough, and if it is more than 6, the cost may increase.

As the discharge hole arrangement density of the rotary net, it is appropriate to have both warp and latitude of 50-90 columns/2.54cm. Also, the discharge rate from the rotary net is preferably in the range of 15-25 cm ³ /m ² . When the discharge amount exceeds 25 cm ³ /m ² , the alkali treatment liquid of the alkali treatment agent may clog the mesh. Conversely, if the discharge amount is less than 15 cm ³ /m ² , the alkali treatment liquid may adhere to the pile head and unevenness may easily occur.

In the plurality of rotating nets, the number and/or arrangement of the discharge holes may be the same or different. For example, after forming a gradient on the pile head with the first rotary net, for the second rotary net, the number and/or arrangement of the discharge holes of the second rotary net can also be changed, so that only the gradient portion can be overlapped. The side with the smallest height is etched. Similarly, for the third and subsequent rotary nets, the number and/or arrangement of the discharge holes may be changed so that only the side with the minimum height of the gradient portion may be overlapped for etching.

The kind of this alkali treatment agent is not particularly limited, for example can apply 30% liquid alkali caustic soda of 30-70% by weight, and 70-30% by weight solid content is divided into the original paste of 15% etching (such as Anda dye ( Co., Ltd., Seruparu 587) The printing paste with a viscosity of 400-800 poises is suitable.

The obtained fleece can also be subjected to known coloring printing (such as the inkjet printing disclosed in JP-A-2000-345483) and conventional dyeing and finishing. Various processing such as conventional waterproof processing, UV shielding or antibacterial agent, deodorant, insect repellant, luminescent agent, retroreflector, and negative ion generator can also be applied additionally.

Example

Examples and comparative examples of the present invention will be described in detail below, but the present invention is not limited thereto. In addition, each measurement item in an Example was measured by the following method.

Boiling water shrinkage

Use a ruler with a circumference of 1.125m to sample the sample 10 times to make a skein, hang the skein on the nail on the scale plate, and hang a load of 1/30 of the total weight of the skein on the lower part, The skein length L1 before processing is read. Then remove the load, put the skein into a kapok bag, and soak in boiling water for 30 minutes. Afterwards, take out the skein, remove moisture with filter paper, and air-dry for 24 hours, then hang it on the peg on the scale plate, hang the same load as above on the lower part, and read the length L2 of the skein after processing. The boiling water shrinkage (BWS) was calculated by the following formula. However, the n number was 5, and the average value was calculated.

BWS(%)=(L1-L2)/L1×100

Curl rate

Use a ruler with a circumference of 1.125m to make a skein yarn with a total fineness of 3333dtex. The skein is hung on the peg on the scale plate, and the initial load of 6g and the load of 600g are hung on the lower part. After reading the length of the skein L0 , Quickly remove the load, remove it from the scale plate at the same time, soak it in boiling water for 30 minutes, and carry out curling treatment. Then take out the skein, remove moisture with filter paper, air dry for 24 hours, then hang it on the scale plate, apply the above load, read the length L1 of the skein after 1 minute, then quickly remove the load, and read the skein after 1 minute length L2. The crimp rate was calculated by the following formula. In addition, the n number was 5, and the average value was calculated.

Curl rate (%)=(L1-L2)/L0×100

Tilt angle A

Cut a square sample with a length of 5cm x 5cm in the longitudinal and transverse directions relative to the longitudinal direction of the fabric, and measure the inclination from the top of the pile head to the bottom of the alkali-treated part using a digital microscope VHX manufactured by Keyence Co., Ltd. The inclination angle A (degrees) between the direction and the horizontal direction. In addition, the n number is 5, and the average value thereof is calculated.

Depth difference H

Cut a square sample with a length of 5 cm x 5 cm in the longitudinal and transverse directions relative to the longitudinal direction of the fabric, and use a digital microscope VHX manufactured by Keyence Co., Ltd. to measure the depth H from the top of the pile head to the bottom of the alkali-treated part. (mm). In addition, the n number is 5, and the average value thereof is calculated.

Gradient section length W

A square sample with a length of 5 cm x 5 cm was cut in the longitudinal and transverse directions relative to the longitudinal direction of the fabric, and the gradient portion length W (mm) as shown in Fig. 1 was measured using a digital microscope VHX manufactured by Keyence Co., Ltd. In addition, the n number is 5, and the average value thereof is calculated.

(6) The number of concave parts per unit area of the gradient part and the ratio of concave parts

Using a scanning electron microscope SX-40 manufactured by Akashi Beam Technology Co., Ltd., the number of recesses (pieces/cm ² ) with an area of 0.05 mm ² or more in the 40% region on the maximum height side of the gradient portion was measured as the number of recesses. Moreover, the concave portion ratio (%) was calculated by the following formula. In addition, the n number is 5, and the average value thereof is calculated.

Recess ratio (%) = (total area of recesses with an area of 0.05mm2 or ^more ) / (area of the 40% area on the maximum height side of the gradient part) × 100

Advanced sense

The sense of luxury was evaluated by 3 testers according to the following 4-level classification.

Level 5: The sense of luxury is particularly ideal.

Level 4: The sense of luxury is ideal.

Level 3: The sense of luxury is good.

Level 2: The sense of luxury is slightly insufficient.

Level 1: Poor sense of quality.

[Example 1]

Common poly(ethylene terephthalate) multifilament yarn (yarn count: 56dtex/24 yarns, boiling water shrinkage: 10%, manufactured by Teijin Textile Co., Ltd.) Ethylene phthalate false twist crimped yarn (yarn count: 84dtex/72 yarns, crimp rate 25%, manufactured by Teijin Textile Co., Ltd.) is a polyester blended yarn obtained by air blending (yarn Thread count: 140dtex/96) is used as the yarn for the pile yarn of the pile fabric, and in addition, as the yarn for the formation of the ground structure, ordinary polyethylene terephthalate monofilament yarn (yarn Count: 56dtex/24, manufactured by Teijin Textile Co., Ltd.), these monofilament yarns are fed into all  of the No. 28 warp knitting machine (manufactured by Karmaiya Co., Ltd.), and knit into the knitting density with the following knitting structure 69 weft/2.54cm, 28 warp/2.54cm pile knitted fabric.

Ground organization: half back stitch (back: 23/10, front: 10/12 knitting method)

The obtained knitted fabric was dyed at 130° C. for 30 minutes with a flow dyeing machine manufactured by Hisaka Seisakusho. After dyeing, carry out conventional processing (full cut fleece→cut pile→splitting→cut pile→pre-shaping) to obtain a cut pile (pile length 2mm) with a knitting density of 64 weft/2.54cm and 35 warp/2.54cm. Pile fabric (pile yarn density 97217dtex/cm ² ).

In this cut pile fabric, polyethylene terephthalate multifilament yarn is used to form pile yarn with high pile yarn height, and polyethylene terephthalate false twist crimped yarn is used to form pile yarn. Pile yarn with low top yarn height.

In addition, prepare 54% by weight of 30% liquid alkali-charged sodium and 46% by weight of the original paste for etching with a solid content of 15% (such as: Adachi Dye Co., Ltd., Celper 587) with a viscosity of 600 poise. Alkaline treatment agent.

Next, use three rotary nets (manufactured by Takagi Sculpture Co., Ltd.) with the following discharge holes and a discharge rate of 20.0 cm ³ /m ² to coat the above-mentioned fleece with the pattern shown in Figure 5 (the dark part is deeply etched). A gradient portion is formed on the pile portion of the head fabric. At this time, the etching portions of the three rotating screens overlap. In addition, in this pattern formed by the pile head, the length of one side of a square as a basic unit is 1 cm.

(spit hole)

Configuration density: both longitude and latitude are 70 columns/2.54cm

The distribution of the discharge holes corresponds to the pattern shown in Figure 5 (the position corresponding to the darkest part is allocated as the discharge hole with the largest aperture, and the discharge hole with a small aperture is gradually allocated towards the light-colored part, and the position corresponding to the lightest part has no holes)

The shape of the spit hole: diameter 0.068mm

After the fabric was dry-heat dried at a temperature of 130°C for 5 minutes, it was treated with high-temperature steam at a temperature of 165°C for 8 minutes, washed with hot water and water, and partially removed the head of the pile by chemical etching to obtain a pile The pile fabric that forms a plurality of gradient parts on the head.

In this fleece, the gradient portion had an inclination angle of 2 degrees, a depth difference H of 0.8 mm, and a gradient portion length W of 10 mm. In addition, in the 40% region on the maximum height side of the gradient portion, the number of concave portions per unit area was 90/cm ² , the concave portion ratio was 2%, and the surface of the gradient portion was smooth with few fine irregularities. And along the gradient of the gradient part, the parts with high pile head height are light-colored, and the parts with low pile head height are shaded and dark, and along the gradient, the light color gradually changes from light to dark, so It has an ideal sense of luxury (level 4).

Example 2

Polyethylene terephthalate multifilament yarn (yarn count: 56dtex/72, manufactured by Teijin Textile Co., Ltd.) was placed in a heater length: 2m, heat treatment temperature: 200°C, heat treatment speed: 500m/ min, overfeed rate: under the condition of 5%, heat treatment is carried out to obtain non-crimp polyethylene terephthalate multifilament yarn with boiling water shrinkage rate of 3%.

In addition, the resin was colored with a black pigment to obtain a polyethylene terephthalate false twist crimped yarn (yarn count: 84 dtex/36 yarns, crimp rate 25%, manufactured by Teijin Textile Co., Ltd.).

In addition, polyethylene terephthalate (manufactured by Teijin Fibers Co., Ltd.) with cationic dye dyeability was melt spun and wound up at a take-up speed of 3500 m/min, and the cationic dye dyeability Partially oriented unstretched polyethylene terephthalate yarn is stretched between the first roll at a temperature of 65°C and the second roll at a temperature of 75°C without heat setting, but at a draw ratio of 1.4 Stretching was performed to obtain a non-crimped polyethylene terephthalate monofilament yarn (yarn count: 56 dtex/24 yarns) having a boiling water shrinkage rate of 45%.

Next, these three kinds of yarns were air blended using a known entanglement nozzle, and the obtained polyester blended yarn (yarn count: 205 dtex/132 yarns) was used as the pile yarn of the pile fabric. Yarn used, in addition, general polyethylene terephthalate monofilament yarn (yarn count: 167dtex/48, boiling water shrinkage rate 10%, Teijin Fiber Co., Ltd. ) system), these monofilament yarns were supplied to all  of a warp knitting machine (manufactured by Calmayya Co., Ltd.) equipped with a No. 28 pole sinker, and the following knitting structures were knitted into a knitting density of 66 picks/2.54cm, 28 warp/2.54cm pile knit.

Organization: Back: 10/12, Front: 10/01

The obtained pile pile fabric was supplied to a machine (manufactured by Nikki Co., Ltd.), and 0.2 mm of the top portion of the pile pile was cut off to form a cut pile. The cut pile fabric is supplied to a dry heat setting machine, and in an open state, heat treatment is carried out at a temperature of 180°C and a time of 45 seconds, so that the non-crimp polyethylene phthalate multifilament yarn in the cut pile is Stabilization, so that the poly(ethylene terephthalate) double false twist crimp processed yarn that is resin-colored by the pigment is fully crimped, and the non-crimp cationic dye-dyeable poly(ethylene terephthalate) single The silk yarn is fully heat-shrinkable.

In the cut pile fabric, non-crimp polyethylene terephthalate multifilament yarn forms the pile yarn 2 with the highest pile height, and non-crimp cationic dye-dyeable polyethylene terephthalate Ester monofilament yarns form pile yarns with the lowest pile height4, and polyethylene terephthalate false-twist crimp processed yarns with resin coloration through pigments form pile yarns with medium pile heights 3.

The obtained cut pile fabric was dyed at 130° C. for 30 minutes using a cationic dye (blue) with a flow dyeing machine manufactured by Hisaka Seisakusho. After dyeing, carry out drying, preset, obtain the pile fabric (pile yarn density is 129,642dtex/ cm ² ). To the pile fabric that obtains, use alkali treatment agent in the same way as in Example 1, and process in the same way.

In this fleece, a gradient portion was formed as shown schematically in FIG. 2 . The gradient angle A of the gradient portion was 2 degrees, the depth difference H was 0.8 mm, and the gradient portion length W was 10 mm. In addition, in the 40% region on the maximum height side of the gradient portion, the number of recesses per unit area was 100/cm ² , the recess ratio was 5%, and the surface of the gradient portion was smooth with few fine irregularities. Further, along the gradient of the gradient part, the highest point of the pile head height is white and black, while the lowest point of the pile head height is a mixed color of black and blue, which is full of ideal sense of luxury (level 5).

Example 3

In Example 2, except that the number of rotary nets was changed to two, the pile head was partially removed by chemical etching in the same manner as in Example 2, and a pile fabric having a gradient formed on the pile head was obtained.

In this pile fabric, the gradient angle A of the gradient part is 2 degrees, the depth difference H is 0.8 mm, the length W of the gradient part is 10 mm, and the number of concave parts per unit area is 120 in the 40% region of the maximum height side of the gradient part. /cm ² , a concave portion ratio of 20%, and a gradient portion surface with few fine irregularities, giving an ideal sense of luxury (grade 4).

Example 4

The fleece obtained in Example 2 was color-printed by the usual inkjet method. The fabric with colored printing exhibits depth depending on the viewing angle, and has a dense gradient appearance, which is excellent.

Example 5

In Example 1, the discharge rate of the rotary net was changed to 26.3 cm ³ /m ² , and the number of the rotary net was changed to 1, and the pile head was partially removed by chemical etching in the same manner as in Example 1, and obtained from the pile The head forms the pile fabric with many gradients of fine unevenness.

In this fleece, the gradient angle A of the gradient portion was 2 degrees, the depth difference H was 0.8 mm, and the gradient portion length W was 10 mm. In addition, in the 40% region of the maximum height side of the gradient portion, the number of recesses per unit area is 150/cm ² , the recess ratio is 25%, and the surface of the gradient portion has fine unevenness, which is acceptable for luxury (grade 3).

Industrial availability

The pile fabric of the present invention has a moderate gradient on the surface of the pile head, which is full of high-end feeling. Therefore, it can be applied to the fields of car interior decoration materials, interior materials, clothing materials, etc., and has high practicability.

Claims (11)

1. fleece, it is the fleece that is constituted by ground organization department with the knitting or woven tissue that includes the organic fiber yarn and the pile portion that comprises polyester fiber, it is characterized in that, in the regional area more than 1 of this pile portion, by the height of pile portion decrescence, form gradient portion with the angle of inclination of 0.5-10 degree.

2. fleece as claimed in claim 1, wherein the different each other pile yarns more than 2 kinds aspect brightness or form and aspect or brightness and form and aspect are contained in this pile portion, change gradually along its color of gradient of gradient portion.

3. fleece as claimed in claim 1, wherein the depth difference of its maximum pile portion height and minimum pile portion height is 0.6-1.0mm in this gradient portion.

4. fleece as claimed in claim 1, wherein this fleece forms pattern by a plurality of gradient portion.

5. fleece as claimed in claim 1, wherein in the maximum pile of this gradient portion portion height side 40% zone, the above fine recess number of area 0.05mm2 be 120/below the cm2.

6. fleece as claimed in claim 5, wherein in the maximum pile of this gradient portion portion height side 40% zone, the gross area of the fine recess that area 0.05mm2 is above is below 20% of this 40% regional gross area.

7. fleece as claimed in claim 1, wherein this fleece carries out direct colour print.

8. the manufacture method of a fleece, it is characterized in that, the pile portion of the fleece that the ground organization department that will have a knitting or woven tissue that includes the organic fiber yarn and the pile portion that comprises polyester fiber are constituted carries out part with chemical method for etching and removes, the height that makes pile portion decrescence forms the gradient portion with 0.5-10 degree angle of inclination thus.

9. the manufacture method of fleece as claimed in claim 8, wherein be used in the pile portion of chemical method for etching before partly removing and contain the pile yarns more than 2 kinds that the pile yarns height differs from one another, and these velvet head lines are different each other aspect brightness or form and aspect or brightness and form and aspect.

10. the manufacture method of fleece as claimed in claim 8 when wherein partly removing pile portion with chemical method for etching, is used to have the spue rotation net of part in aperture in hole of cumulative etch processes liquid.

11., wherein use 2-5 rotation net to carry out chemical etching continuously overlappingly and handle as the manufacture method of the fleece of claim 10.

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