JP4931046B2 - Towel with excellent pile retention - Google Patents

Description

  The present invention relates to a towel obtained from a woven fabric. More specifically, the present invention relates to a towel that prevents pile yarn from dropping and maintains a texture and durability for a long period of time.

  Conventionally, towels are made by forming a ground structure with warps and wefts and forming a pile loop with warps for pile yarns. The pile yarn is anchored only by the resistance of the contact portion with respect to the weft, and the anchoring action is not sufficient, so that the pile is likely to come off. In addition, towel fabrics using synthetic fibers such as nylon, polyester, rayon, etc. in the ground structure are concerned about the problem that pile slippage is promoted due to deterioration and collapse of the synthetic fibers with time.

In order to solve these problems, in order to avoid pile omission, ground warp yarns and pile yarns are alternately arranged, and towel fabrics woven with a three-pick structure using three weft yarns, pile yarns and ground yarns are used. A towel fabric is disclosed in which warp yarns are used in a ratio of 1: 2, and ground warp yarns arranged on both sides of each pile yarn are arranged in the same floating state with respect to the weft yarns. In addition, the pile portion and the non-pile portion have a weft stripe pattern alternately arranged in the warp direction, and the ground texture warp and pile yarn are inserted as the warp, and the ground texture weft is inserted as the weft, and as the ground texture weft in the non-pile portion A method of manufacturing a towel by heat-treating a towel fabric formed by inserting shrink yarns at an arbitrary interval is disclosed. However, the pile yarn remains tethered only by the contact portion with respect to the weft, and it is not sufficient for solving the problem of the pile coming off.

Japanese Patent Laid-Open No. 5-230738 JP-A-8-196465

In such a conventional pile fabric, pile yarn is inserted into the warp, and when used as a towel, the pile ring is stretched by catching on a nail or a protrusion, and the towel may be pulled. Then, this invention makes it a subject to provide the towel which does not attract to cloth | dough, even if a nail | claw and a procession | hook are caught at the time of the use in the state which hold | maintained the original touch and water retention of the towel stably.

As a result of intensive research to solve the above-mentioned problems, the inventors of the present invention have developed a towel fabric weft consisting of pile yarn, weft and warp mainly composed of natural fibers excellent in skin touch, water retention and water absorption. A part of spun yarn made of heat-fusible composite fiber is placed and heat treated in the finishing process. The present invention has been completed by finding that a towel with no fabric pulling is provided.

The present invention has the following configuration.
1) A pile fabric towel including pile yarn, warp yarn and weft yarn, wherein the pile yarn, warp yarn and weft yarn is mainly composed of spun yarn containing natural fibers, and 3-10 pile fabric textures. A weft yarn comprising a pick structure having a weft as one unit, wherein at least one weft in the unit is a spun yarn containing a heat-fusible conjugate fiber, and the weft yarn containing the heat-fusible conjugate fiber A towel excellent in pile retention, wherein pile yarns are tethered to each other and pile yarns are heat-sealed to the wefts by the heat-fusible conjugate fiber.

2) The heat-fusible composite fiber is composed of a high melting point component and a low melting point component, and the low melting point component continuously forms at least a part of the fiber surface in the length direction. 2. The towel having excellent pile retention characteristics according to the above item 1, which contains a modified polyethylene having at least one functional group of a hydroxyl group, an amino group and an epoxy group.

3) The towel having excellent pile retention according to the above item 2, wherein the low melting point component of the heat-fusible conjugate fiber is polyethylene and the high melting point component is polypropylene or polyethylene terephthalate.

4) The pile holding according to any one of the above items 1 to 3, wherein the heat-fusible conjugate fiber of the woven fabric is woven with the pile yarn by softening the low melting point component. Excellent towel.

5) A towel excellent in pile retention according to any one of items 1 to 4, wherein the pile yarn, warp yarn and weft yarn are composed of spun yarn containing 50% by weight or more of natural fibers. .

The towel excellent in pile retention of the present invention is a towel woven fabric composed of pile yarns, warps and wefts mainly composed of natural fibers. By heat-treating at a temperature above the melting point of the low-melting component of the fusible composite fiber and below the melting point of the high-melting component, the pile yarn, the weft and the warp can be heat-fused to obtain a towel with excellent pile retention. Therefore, it is possible to provide a towel excellent in touch, water absorption and water retention. The towel of the present invention can be used for towel handkerchiefs, hand towels, face towels, bath towels, towels, sheets, bath mats, residential mats, and the like.

Hereinafter, the present invention will be described in detail.
Towels can be manufactured using a general-purpose towel manufacturing loom, such as a jacquard loom or a plain loom, as it is, under the methods and conditions normally used.

The pile yarn, warp and weft used for the towel of the present invention are mainly composed of spun yarn containing 50% by weight or more of natural fiber, and examples of the natural fiber include cotton yarn, silk yarn, hemp yarn, etc. Cotton yarn having high water absorption and good touch is preferable. It is also possible to use a spun yarn in which silk yarn, hemp yarn, etc. are blended mainly with cotton yarn, or a synthetic fiber such as rayon fiber or polyester fiber is blended with natural fiber. In terms of water absorption and touch, the pile yarn is composed of spun yarn containing 60% by weight or more of natural fiber, the warp yarn is composed of spun yarn containing 60% or more of natural fiber, and the weft is 50% by weight. It is particularly preferable to use a spun yarn containing the above natural fibers. In addition, the weft of the towel of the present invention is a spun yarn in which at least one weft in one unit includes a heat-fusible conjugate fiber in a pick structure structured with 3 to 10 wefts as one unit. However, it is preferable that the ratio of the natural fibers contained in the whole unit is 50% by weight or more, and the content of the natural fibers in one weft is not limited.

Spun yarns mainly containing natural fibers can be used by appropriately selecting usually available spun yarns, and the thickness (count) of pile yarn, weft yarn and warp yarn can be appropriately selected according to the required quality. 16th, 20th, 30th, 40th, etc. can be cited as examples.

  The towel of the present invention is a spun yarn in which at least one weft contains a heat-fusible conjugate fiber in one unit in a pick structure that is composed of 3 to 10 wefts as one unit, and the heat-fusible conjugate fiber As the spun yarn containing, a composite fiber obtained by composite spinning using two or more kinds of spinnable thermoplastic resins as a raw material is used.

Examples of the thermoplastic resin include polypropylene, high density polyethylene, low density polyethylene, linear low density polyethylene, polyolefins such as binary or ternary copolymers of propylene and other α-olefins, polyamides, polyethylene Examples thereof include terephthalate, polybutylene terephthalate, low melting point polyester obtained by copolymerizing diol and terephthalic acid / isophthalic acid, polyesters such as polyester elastomer, fluororesin, and a mixture of the above resins.

  Examples of the composite form of the heat-fusible composite fiber include a sheath core type, a parallel type, a multilayer type having three or more layers, a hollow multilayer type, and a modified multilayer type. At this time, the combination of the thermoplastic resins preferably has a melting point difference of 10 ° C. or more, and among the thermoplastic resins constituting the fibers, the low melting point thermoplastic resin is exposed on at least a part of the fiber surface, and further the fibers It is preferable that the structure is continuous along the length direction. As a result, the spun yarn including the heat-fusible conjugate fiber used as a part of the weft yarn is heat-treated at a temperature equal to or higher than the softening point or the melting point of the low-melting thermoplastic resin and less than the melting point of the high-melting thermoplastic resin. The pile yarn can be heat-sealed with the pile yarn at the tethered portion with the pile yarn woven into the warp yarn, thereby improving the pile yarn retention.

  Thermal fusion of spun yarn containing heat-fusible composite fiber used as part of the weft and pile yarn woven into the warp can be performed in the normal pre-setting process and finishing setting process, and hot air circulation It is preferable to use a dryer or a continuous heat setting machine. It is desirable to perform heat treatment at a temperature not lower than the melting point of the low-melting component of the heat-fusible conjugate fiber and lower than the melting point of the high-melting component, and to arbitrarily set the set time with a woven fabric.

  The combination of the low melting point component and the high melting point component in the heat-fusible composite fiber includes high density polyethylene / polypropylene, low density polyethylene / polypropylene, linear low density polyethylene / polypropylene, low density polyethylene / propylene-ethylene-butene- 1 Crystalline copolymer, ethylene-propylene copolymer / polypropylene, high density polyethylene / polyethylene terephthalate, nylon-6 / nylon 66, low melting point polyester / polyethylene terephthalate, polypropylene / polyethylene terephthalate, polyvinylidene fluoride / polyethylene terephthalate, wire A mixture of low-density polyethylene and high-density polyethylene / polyethylene can be exemplified. Preferably, the composite fiber is made of a polyolefin-based component. Examples of such low-melting point thermoplastic resin / high-melting point thermoplastic resin combinations include high-density polyethylene / polypropylene, ethylene-propylene copolymer / polypropylene. Etc.

  In particular, in order to prevent the pile yarn from coming off in the present invention, in order to improve the fusion property at the tether point between the heat-fusible composite fiber and the pile yarn woven into the warp yarn, it is reactive to the low melting point component of the fiber. It is desirable to include a modified polyethylene having a functional group. Examples of the reactive functional group include groups such as a hydroxyl group, amino, carbonyl, carboxyl, and epoxy. The modified polyethylene can be polymerized using the vinyl monomer having the reactive functional group, and any of copolymers such as block, random, ladder, and graft copolymers can be used. As the vinyl monomer having a reactive functional group, at least one unsaturated carboxylic acid selected from maleic anhydride, maleic acid, acrylic acid, methacrylic acid, fumaric acid, itaconic acid, a derivative thereof, or an anhydride thereof is used. Containing vinyl monomers, styrenes such as styrene and α-methylstyrene, methacrylic acid esters such as methyl methacrylate, ethyl methacrylate, 2-hydroxyethyl methacrylate, dimethylaminoethyl methacrylate, or similar acrylic esters, etc. At least one vinyl monomer, glycidyl acrylate, glycidyl methacrylate, butenecarboxylic acid ester, allyl glycidyl ether, 3.4-epoxybutene, 5.5-epoxy-1-hexene, vinylcyclohexene monoxide, etc. And vinyl monomers containing one.

  In general, the modified polyethylene preferably has the reactive functional group at a ratio of 0.05 to 2.0 mol / kg with respect to the total weight, and has a modification rate of 0.05 to 0.2 mol / kg. More preferably, modified polyethylene is used.

  Among the modified polyethylenes, a modified polyethylene that is a graft copolymer can be used more preferably, and the modification rate is preferably as high as possible within a range that does not interfere with fiber processability.

As the trunk polymer of the modified polyethylene, high-density polyethylene, linear low-density polyethylene, or low-density polyethylene is used. These are polymers having a density of 0.90 to 0.97 g / cm ³ and a melting point of about 100 to 135 ° C. Among these polymers, polyethylene is preferable in view of ease of graft copolymerization, and high density polyethylene excellent in fiber processability is more preferable.

  Examples of the resin having a reactive functional group contained in the low-melting-point component of the heat-fusible composite fiber include modified polypropylene and modified polybutene in which polypropylene or polybutene-1 is used as a trunk polymer in addition to modified polyethylene. It is valid. As the backbone polymer polypropylene, a propylene homopolymer or a copolymer of propylene and other α-olefins containing propylene as a main component is used. These are polymers having a melting point of about 130 to 170 ° C. as a trunk polymer. Polybutene-1 is a polymer having a melting point of about 110 to 130 ° C. as a trunk polymer.

  As the low melting point component containing the modified polyethylene, a modified polyethylene alone, a mixture of at least two kinds of modified polyethylene, a mixture of at least one kind of modified polyethylene and another thermoplastic resin, or the like can be used.

  The weight ratio of the low melting point component to the high melting point in the heat-fusible composite fiber is 10 to 90% by weight for the low melting point component and 10 to 90% by weight for the high melting point component, preferably 30 to 70% by weight for the low melting point component. %, The high melting point component is 70 to 30% by weight. It is preferable that the amount of the low melting point component is 10% by weight or more in order to sufficiently heat-bond with the pile yarn to be woven and to improve the pile retention, and it is sufficient to obtain a spun yarn. This is because the amount of the low melting point component is preferably 90% by weight or less in order to maintain the fiber strength.

The number of crimps, crimp shape, and fiber length of the heat-fusible conjugate fiber are not particularly limited as long as they can be processed without hindrance in the process of obtaining the spun yarn.

  The spun yarn including the heat-fusible conjugate fiber constituting a part of the weft constituting the towel of the present invention can be obtained by a general spinning method. As an example, a thermoplastic composite fiber is opened, and is pulled by a carding machine needle and aligned in the length direction, and a bundle of these is stretched to obtain a sliver having a uniform thickness. Thereafter, the sliver is stretched to a certain thickness, and a necessary twist is added to obtain a spun yarn.

  The spun yarn containing the heat-fusible conjugate fiber is preferably used in the range of 20 to 60. In order to prevent a decrease in the texture due to the thick spun yarn and to maintain sufficient water absorption and water retention as a towel, it is preferable that the spun yarn is 20th or thinner, and the spun yarn is spun to improve the texture. This is because it is preferable that the number is 60 or thicker in order not to cause yarn breakage during processing even if the yarn is thinned.

  The spun yarn including the heat-fusible conjugate fiber can be a single spun yarn of the heat-fusible conjugate fiber, but can also be a blended yarn with natural fibers such as cotton yarn and silk yarn. By using a blended yarn with a heat-fusible conjugate fiber as a part of the weft, even if the proportion of the weft used in the pick unit increases, heat fusion per warp and pile yarn anchoring point can be achieved. While restraining, the heat-sealing power at all tethers can be increased to prevent the pile from coming off. The blend ratio of the heat-fusible conjugate fiber and the natural fiber is preferably 20% by weight or more of the heat-fusible conjugate fiber. The blended yarn can be obtained by opening the fiber while mixing the thermoplastic composite fiber and natural fiber such as cotton and twisting the sliver with a carding machine.

Anti-oxidant, light stabilizer, ultraviolet absorber, neutralizer, nucleating agent, epoxy stabilizer, lubricant, antibacterial agent, flame retardant, within the range not impeding the effect of the present invention to the heat-fusible conjugate fiber Pigments, plasticizers and other thermoplastic resins can be added.

The towel excellent in pile retention of the present invention is a spun yarn in which at least one of the pick units includes a heat-fusible conjugate fiber in a pick structure having 3 to 10 wefts as one unit. Desirable pick structures are 3 to 10 pick structures, and spun yarns containing heat-fusible fibers are desirably used within a range not exceeding 2/3 per pick structure. When used in a range not exceeding 2/3, the ratio of the wefts to be heat-sealed by the heat treatment in the finishing process is suppressed, and a towel having a sufficiently soft texture can be obtained.

The pile yarn is tethered with a weft yarn including at least one heat-fusible fiber disposed in the pick unit. It is considered that the pile yarn is tethered with the weft yarn containing the heat-fusible fiber and is heat-treated in the finishing process, so that the pile yarn and the weft yarn containing the heat-fusible fiber are heat-sealed to increase pile retention.

The heat-fusible conjugate fiber may be further arranged on the warp as long as it is arranged on at least one of the wefts in the pick unit. When it is arranged on the warp, it is preferably arranged at a position adjacent to the pile yarn. By being arranged at a position adjacent to the pile yarn, the warp yarn including the pile yarn and the heat-adhesive conjugate fiber can be thermally fused in the heat treatment step.

Hereinafter, although an example and a comparative example explain the present invention, the present invention is not limited to these. In addition, the measuring method of the physical-property value shown in the Example and the comparative example is shown below.
(1) The pile pull-out resistance was measured according to JIS L1075 B method.
(2) The texture of the towel was tested by five panelists and judged good when all five were soft, and poor when three or more panelists were judged to be hard. However, the towel obtained in Comparative Example 1 was used as a reference.

Example 1
A pile loop using a general-purpose jacquard loom using 20th cotton yarn for ground warp and pile yarn and spun yarn consisting of 20th cotton yarn and 20th heat-fusible composite fiber for weft yarn A towel having a six-pick structure was produced, in which six weft yarns having 1 are used as one unit.
As the heat-fusible conjugate fiber, high-density polyethylene having a melting point of 130 ° C. containing 10% by weight of maleic anhydride grafted polyethylene (maleic anhydride content 1% by weight) as a low melting point component is arranged on the sheath side, and the core side Is a structure in which polypropylene having a melting point of 160 ° C. is arranged so that the sheath-core ratio is a composite ratio of 50/50. The spun yarn made of the heat-fusible conjugate fiber used as the weft was used for the fifth pick (1/6 of the weft). The woven towel was heat-set at 140 ° C. for 5 minutes in the finishing step to heat-seal the pile yarn and the heat-fusible conjugate fiber, thereby obtaining a towel having excellent pile retention.

(Example 2)
The same procedure as in Example 1 was performed, but a towel having a three-pick structure with three wefts as one unit was used, and a spun yarn made of heat-fusible conjugate fiber was used for the second pick (one third of the weft). .

(Example 3)
The same procedure as in Example 2, but spun yarns made of heat-fusible conjugate fibers were used for the 1st and 3rd picks (2/3 of the weft yarns).

(Reference example)
The same method as in Example 1 was performed except that all the wefts were blended yarns of 30% heat-fusible conjugate fiber and 70% cotton yarn.

(Comparative Example 1)
The same method as in Example 1 was carried out except that spun yarn made of cotton was used for all the warp, weft, and pile yarn.

(Comparative Example 2)
The same method as in Example 1 was carried out except that only spun yarn made of heat-fusible conjugate fiber was used for the weft.

It has been shown that the towel with excellent pile retention of the present invention has high pile pull-out resistance as compared with the case where only cotton yarn is used as the weft, and has excellent pile retention. On the other hand, when the spun yarn made of heat-fusible conjugate fiber is used for all the wefts, the pile retention is the highest, but the towel is finished slightly harder. However, a towel with a better texture could be obtained by changing the heat-fusible conjugate fiber to a blended yarn with cotton yarn.

The towel excellent in pile retention of the present invention can be used for towel handkerchiefs, hand towels, face towels, bath towels, towels, sheets, bath mats, residential mats and the like.

Claims (5)

A pile fabric towel including pile yarn, warp yarn and weft yarn, wherein the pile yarn, warp yarn and weft yarn are mainly composed of spun yarn containing natural fibers, and the pile woven structure comprises 3 to 10 weft yarns. It is composed of a pick structure organized as one unit, and at least one weft in the one unit is a spun yarn containing a heat-fusible conjugate fiber, and the heat-fusible conjugate fiber comprises a high melting point component and It consists of a low melting point component, and the low melting point component is formed continuously in the length direction on at least a part of the fiber surface. The low melting point component has at least one functional group of carboxyl group, hydroxyl group, amino group and epoxy group. A modified polyethylene having a group, the modified polyethylene has the functional group at a rate of 0.05 to 0.2 mol / kg, and the spun yarn including the heat-fusible conjugate fiber has a pick structure Or in a range that does not exceed 2/3, and then the pile yarn anchoring weft containing the heat-fusible composite fiber, and by the heat-fusible composite fibers, the pile yarn is thermally fused to said weft A towel with excellent pile retention characteristics. The towel excellent in pile retention according to claim 1, wherein the spun yarn containing the heat-fusible conjugate fiber is in a range of 20 to 60 . The towel with excellent pile retention according to claim 1 or 2, wherein the low melting point component of the heat-fusible conjugate fiber is polyethylene and the high melting point component is polypropylene or polyethylene terephthalate.   The pile retention property according to any one of claims 1 to 3, wherein the heat-fusible conjugate fiber of the woven fabric is woven with the pile yarn by softening of the low melting point component. Excellent towel.   The towel with excellent pile retention according to any one of claims 1 to 4, wherein the pile yarn, warp yarn and weft yarn are made of spun yarn containing 50% by weight or more of natural fibers.