JP6672307B2 - Pile fabric and manufacturing method thereof - Google Patents

Description

  The present invention relates to a pile fabric in which pile fibers are prevented from coming off and the pile fabric is enhanced in flexibility, and a method for producing the same.

  2. Description of the Related Art A pile fabric is conventionally known as an imitation fur, a fake fur, a bore or the like as a fabric having an appearance similar to fur. These are made from pile knits and pile fabrics. In the case of a knitting pile, it is mainly knitted by a seal milling machine and a sliver knitting machine (circular knitting machine), and in each case, pile fibers are cut. In the case of knitting with a double raschel machine of a warp knitting machine, knitting is performed by forming a ground structure in double and simultaneously tying a binding yarn between the ground structures and cutting the middle of the binding yarn. In the case of the weaving method, two woven fabrics are simultaneously cut by using a velvet loom and a moquette loom to tie the binding yarn between the upper and lower ground structures and the base fabric with a knife. Weave. However, these woven and knitted fabrics, particularly knitted fabrics such as high pile fabrics, have a problem that there are many hair loss.

  In order to prevent hair loss of the pile fabric, there are proposals of mixing low-melting fibers with pile fibers (Patent Document 1) and proposals of mixing low-melting fibers with ground yarns constituting a ground structure (Patent Documents 2 and 3). . However, in all of these proposals, since the entire fabric is heated at a temperature equal to or higher than the melting point of the low-melting fiber, the entire ground structure or the pile fiber is also fused, resulting in a rough and hard texture. is there.

  Therefore, in Patent Document 4, in a pile fabric using specific fibers, only a specific portion of the pile fibers on the back surface is fused to prevent pile fibers from coming off without impairing the texture of the raised surface. Suggested.

JP-A-6-081248 JP 2000-314048 A JP-A-7-048765 International Publication No. 2011/055455

  However, in the pile fabric described in Patent Literature 4, since the pile fibers are fused on the back surface of the pile fabric, the back surface of the pile fabric may be hard, and thus the pile fabric may be hard.

  The present invention, in order to solve the above problems, in a pile fabric in which at least a part of the pile fiber is fused on the back surface of the pile fabric, while suppressing the detachment of the pile fiber, while improving the flexibility of the pile fabric. Pile fabric and a method for producing the same.

  The present invention includes a ground structure, and pile fibers entangled with ground yarns constituting the ground structure and raised on the surface of the ground structure, wherein the pile fibers are at least one selected from the group consisting of acrylic fibers and acrylic fibers. In the pile fabric, the softening point of the pile fibers is lower than the fibers constituting the ground structure, and among the pile fibers entangled with the ground yarns forming the ground structure, the pile fibers are raised on the surface of the ground structure. The pile fibers are not fused, and at least a part of the pile fibers arranged outside the ground yarn constituting the ground structure on the back surface of the ground structure is fused, and For the pile fiber, an amino-modified silicone-based softener, an epoxy-modified silicone-based softener and a carboxyl-modified silicone-based softener are based on 100 parts by weight of the pile fiber. One or more organic modified silicone softening agent selected from Ranaru group relates pile fabric which is characterized in that it is deposited 0.4 parts by weight or more.

  The present invention is also the method for producing a pile fabric, comprising a ground structure, and pile fibers entangled with ground yarns constituting the ground structure and raised on the surface of the ground structure, wherein the pile fibers are acrylic. The pile fibers include at least one fiber selected from the group consisting of fibers and acrylic fibers, and the pile fibers have a softening point lower than the fibers constituting the ground structure, and the pile fibers on the back surface of the pile fabric include: 0.4 parts by weight of one or more organic-modified silicone-based softeners selected from the group consisting of amino-modified silicone-based softeners, epoxy-modified silicone-based softeners and carboxyl-modified silicone-based softeners per 100 parts by weight of the pile fiber. The piled fabric is adhered to the back side of the pile fabric at the softening point of the pile fiber or more and the softening point of the fiber constituting the ground structure. By performing thermocompression bonding at a full temperature, among pile fibers entangled with the ground yarns constituting the ground structure, pile fibers raised on the surface of the ground structure are not fused, and the ground fibers are formed on the back surface of the ground structure. The present invention relates to a method for producing a pile fabric, characterized by fusing at least a part of pile fibers arranged outside ground yarns constituting a structure.

  Preferably, the organic-modified silicone-based softener is an amino-modified silicone-based softener. Preferably, the pile fibers are acrylic fibers. The ground yarn is preferably a polyester fiber yarn. It is preferable that 0.4 to 2.5 parts by weight of the organic-modified silicone-based softener is adhered to 100 parts by weight of the pile fiber on the back surface of the pile fabric.

  ADVANTAGE OF THE INVENTION This invention can provide the pile fabric which improved the flexibility of the pile fabric, suppressing the hair removal of a pile fiber. Further, according to the pile fabric manufacturing method of the present invention, it is possible to easily manufacture a pile fabric in which the flexibility of the pile fabric is improved while preventing the pile fibers from coming off.

FIG. 1 is a schematic diagram illustrating a positional relationship between ground yarns and pile fibers entangled in the ground yarns in a high pile fabric according to an embodiment of the pile fabric of the present invention. FIG. 2 is a manufacturing process diagram showing one embodiment of the method for manufacturing a pile fabric of the present invention. FIG. 3 is a schematic diagram illustrating a method for measuring the amount of hair loss of a pile fabric in the embodiment of the present invention. FIG. 4 is a schematic sectional view illustrating a method for evaluating the flexibility of the pile fabric in the embodiment of the present invention.

  The inventors of the present invention, as a pile fiber at least one fiber selected from the group consisting of acrylic fiber and acrylic fiber, among the pile fibers disposed outside the pile fiber ground yarn on the back surface of the pile fabric In a pile fabric in which at least a part of the pile fibers was fused, studies were repeatedly made on improving the flexibility of the pile fabric while suppressing hair loss of the pile fibers. As a result, the pile fiber on the back surface of the pile fabric, based on 100 parts by weight of the pile fiber, one or more kinds selected from the group consisting of amino-modified silicone softener, epoxy-modified silicone softener and carboxyl-modified silicone softener. The present inventors have found that by adhering 0.4 parts by weight or more of the organic-modified silicone-based softening agent, it is possible to improve the flexibility of the pile fabric while suppressing the detachment of the pile fibers, and have reached the present invention. Softeners (also referred to as softeners) generally impart softness, slipperiness, etc. to the surface of the fiber, but in the present application, surprisingly, a specific softener is added to the pile fibers on the back side of the pile fabric. It has been found that by adhering a predetermined amount to the pile, it is possible to improve the flexibility of the pile fabric while suppressing the detachment of the pile fibers.

  The pile fabric of the present invention is a pile fabric including a ground structure and pile fibers entangled with ground yarns constituting the ground structure and raised on the surface of the ground structure. The pile fabric is not particularly limited, and examples thereof include a high pile fabric, a bore pile, and a tufted carpet. It is particularly suitable for high pile fabrics in which hair loss easily occurs. Although the high pile fabric is not particularly limited, for example, it is preferable that the length of the pile fiber of the nap portion is 15 to 100 mm.

  The high pile fabric is a pile knitted fabric, and the ground structure is a knitted ground structure. In detail, the high pile fabric includes a knitted ground structure and pile fibers that are entangled with the ground yarns constituting the ground structure and are raised on the surface of the ground structure. In the case of a high pile fabric, since the ground structure is knitted, a structure excellent in elasticity can be formed. A knitted fabric is generally formed by forming one or more yarns into a loop, hooking the loop, and continuing to form the next new loop, and successively looping the loops in a plane to form a fabric. is there. And weft knitting is performed in the horizontal direction depending on whether the yarn reciprocates left and right while forming a loop to form a flat fabric, or spirally to form a tubular fabric. A knitted knitted fabric is a knitted knitted fabric in which a large number of warp yarns arranged in order form a loop and are connected to adjacent left and right warp yarns by a loop to form a fabric. The flat knitting knitting includes knitting methods such as flat knitting, rubber knitting, and pearl knitting, and the warp knitting knitting includes knitting methods such as denby knitting, cord knitting, atlas knitting, and chain knitting. As a method of knitting the ground structure of the high pile fabric, a flat knitted knit is preferable from the viewpoint of commercialization and productivity.

  In the present invention, the arrangement of the pile fibers with respect to the knit of the ground structure may be such that the pile fibers are entangled with all the loops of the ground yarn constituting the knit of the ground structure, or the ground yarn forming the knitted fabric. May be arranged so as to have a portion in which pile fibers are not entangled in the wale direction and / or the course direction.

  The fiber constituting the ground structure, that is, the fiber constituting the ground yarn may be any fiber having a higher softening point than the pile fiber, and is not particularly limited. For example, polyester fibers, cellulosic fibers and the like can be mentioned. Examples of the polyester fiber include a synthetic fiber obtained by spinning a resin composition containing a polyester resin such as polyethylene terephthalate. Examples of the cellulosic fiber include cotton and the like. It is preferable that the ground yarn is a polyester fiber yarn from the viewpoint of more effectively suppressing hair loss of the pile fiber and increasing the flexibility of the pile fabric.

  The pile fibers have a lower softening point than the fibers constituting the ground structure, and among the pile fibers entangled with the ground yarn, some or all of the pile fibers arranged outside the ground yarn on the back surface of the ground structure are fused. The pile fibers that are raised on the surface of the ground structure are not fused. This means is not particularly limited, but it is preferable to perform thermocompression bonding at a temperature not lower than the softening point of the pile fibers and lower than the softening point of the fibers constituting the ground structure from the back side of the pile fabric.

  The pile fibers include acrylic fibers and / or acrylic fibers. Thereby, a pile fabric excellent in texture is obtained. Generally, when a thermoplastic fiber is used as a pile fiber and polishing is performed at a temperature higher than the melting point or softening point of the thermoplastic fiber, the pile fiber on the surface of the pile fabric is burnt or melted. A pile fabric having good appearance and texture cannot be obtained. In addition, if the polishing is performed at a temperature equal to or lower than the glass transition point of the thermoplastic fiber, the pile fabric having good appearance and texture cannot be obtained because the pile fiber on the surface of the pile fabric does not elongate. On the other hand, crimps of acrylic fibers and acrylic fibers extend even at a temperature lower than the melting point. And since the glass transition point of acrylic fiber and acrylic fiber is about 100 ° C and the softening point is about 150 to 230 ° C, when acrylic fiber and / or acrylic fiber is used for the pile fiber, Polishing can be performed at a temperature equal to or lower than the softening point, for example, at 100 to 150 ° C. Further, the crimp of the acrylic fiber and the acrylic fiber tends to be stretched more easily than the fiber of another material, so that a pile fabric having a good appearance and a good texture can be obtained.

  In addition, the pile fibers may include synthetic fibers or other fibers obtained by spinning a resin composition containing a polyester resin such as polyethylene terephthalate and polytrimethylene terephthalate, as long as the effects of the present invention are not impaired. .

  The pile fiber is not particularly limited as long as the softening point is lower than the fiber constituting the ground yarn, but the difference in softening point between the fiber constituting the ground yarn and the pile fiber is preferably 10 ° C. or more, It is preferably at least 20 ° C, particularly preferably at least 30 ° C. When there is a difference of 10 ° C. or more, only a part or all of the pile fibers disposed outside the ground yarn on the back surface of the pile fabric are bonded by thermocompression bonding, and the pile fibers are raised on the surface of the ground structure. Is not easily thermally bonded (not fused).

  All of the pile fibers may be fibers that soften at a predetermined temperature, or may be a mixed fiber of fibers that soften at different temperatures. When the pile fiber is a mixed fiber of fibers softening at different temperatures, the fibers softening at a relatively low temperature are mixed in an amount of 20% by weight or more, and the fibers softening at a relatively low temperature are thermocompressed. Preferably, fibers softening at a relatively low temperature are mixed in an amount of 50% by weight or more.

  In the embodiment of the present invention, the softening point is a softening temperature before melting or decomposing. For example, the softening point of an acrylic fiber is 190 to 232 ° C., and the softening point of an acrylic fiber is 150 to 220 ° C. (“Chemical Encyclopedia”, Kyoritsu Shuppan, pp. 727-729, issued June 1, 1993. Reference value ”).

  In the embodiment of the present invention, the acrylic fiber refers to a fiber composed of a polymer obtained by polymerizing a composition containing 85% by weight or more of acrylonitrile and 15% by weight or less of another copolymerizable monomer. . The acrylic fiber is a polymer obtained by polymerizing a composition containing acrylonitrile in an amount of 35% by weight or more and less than 85% by weight and other copolymerizable monomers in an amount of more than 15% by weight and 65% by weight or less. Fiber

  In the embodiment of the present invention, the other copolymerizable monomer is not particularly limited as long as it is a monomer copolymerizable with acrylonitrile. For example, vinyl halide represented by vinyl chloride, vinyl bromide and the like; vinylidene halide represented by vinylidene chloride and vinylidene bromide; allylsulfonic acid, methallylsulfonic acid, styrenesulfonic acid, isoprenesulfonic acid, -Sulfonic acid-containing monomers such as acrylamide-2-methylpropanesulfonic acid and the like, metal salts and amine salts of these sulfonic acid-containing monomers; lower alkyl esters of acrylic acid and methacrylic acid, aminoalkyl esters substituted with N-alkyl , N, N-alkyl-substituted aminoalkyl esters and glycidyl esters; acrylamide, methacrylamide and their N-alkyl-substituted, N, N-alkyl-substituted carboxyls represented by acrylic acid, methacrylic acid, itaconic acid, etc. Base Vinyl-containing monomers and anionic vinyl monomers such as sodium, potassium or ammonium salts thereof; cationic vinyl represented by quaternized aminoalkyl esters of acrylic acid and quaternary aminoalkyl esters of methacrylic acid Monomer; vinyl group-containing lower alkyl ether; vinyl group-containing lower carboxylic acid ester represented by vinyl acetate; and styrene. One of these monomers may be used, or two or more thereof may be used in combination.

  As other copolymerizable monomers, it is preferable to use one or more monomers selected from the group consisting of metal halides of vinyl halides, vinylidene halides and sulfonic acid-containing monomers, and vinyl chloride, vinylidene chloride and styrene sulfonic acid are preferably used. It is more preferable to use one or more monomers selected from the group consisting of sodium.

  The pile fiber is preferably an acrylic fiber, contains acrylonitrile in an amount of 35% by weight or more and less than 85% by weight, and contains vinyl chloride and / or vinylidene chloride and other copolymerizable monomers in a total amount of more than 15% by weight. Acrylic fibers obtained by polymerizing a composition containing 65% by weight or less are more preferable.

  In the embodiment of the present invention, the combination of the types of the fibers constituting the ground yarn and the pile fibers is not particularly limited as long as the above conditions are satisfied, and specific examples thereof will be shown below.

  When polyethylene terephthalate (PET, softening point: about 258 ° C.) fiber is used as the fiber constituting the ground yarn, for example, an acrylic fiber or a mixed fiber of an acrylic fiber and an acrylic fiber is preferably used as the pile fiber. . The following fibers can be preferably used as the acrylic fibers.

(1) Vinyl chloride-acrylonitrile fiber (for example, manufactured by Kaneka Corporation, trade name "Kanecaron", softening point 150-220 ° C, literature value)
(2) Vinylidene chloride-acrylonitrile fiber (softening point 150-220 ° C, literature value)

  For example, when cotton (cotton, no softening point) fiber is used as the fiber constituting the ground yarn, it is preferable to use an acrylic fiber as the pile fiber. In addition, examples of the acrylic fiber include Exlan K691 (trade name: softening point 190 to 232 ° C., literature value) manufactured by Exlan Corporation.

  At least one organic-modified silicone-based softener selected from the group consisting of amino-modified silicone-based softener, epoxy-modified silicone-based softener and carboxyl-modified silicone-based softener is attached to the pile fibers on at least the back surface of the pile fabric. ing. An organically modified silicone softener such as an amino-modified silicone softener may or may not adhere to the pile fibers on the surface of the pile fabric. From the viewpoint of more effectively suppressing hair loss while improving the flexibility of the pile fabric, the adhesion amount of an organic-modified silicone-based softener such as an amino-modified silicone-based softener on pile fibers on the back surface of the pile fabric is reduced. It is preferable that the amount of the organic-modified silicone-based softener such as the amino-modified silicone-based softener on the pile fibers on the surface of the fabric is higher than the amount of the organic-modified silicone-based softener. In the following, unless otherwise specified, "organic modified silicone softener" means one or more selected from the group consisting of amino-modified silicone softener, epoxy-modified silicone softener and carboxyl-modified silicone softener. . The amino-modified silicone softener is not particularly limited as long as it is a softener containing a polysiloxane containing an amino functional group as a main component. The epoxy-modified silicone-based softener is not particularly limited as long as it is a softener containing a polysiloxane containing an epoxy functional group as a main component. The carboxyl-modified silicone softener is not particularly limited as long as it is a softener containing a polysiloxane containing an epoxy functional group as a main component. Here, the “main component” is preferably contained in an amount of at least 40% by weight, more preferably at least 50% by weight, and more preferably at least 60% by weight, based on the total weight of the solid content in the softener. Is still more preferred, and even more preferably 70% by weight or more. Note that a softener other than the organically modified silicone softener may be attached to the pile fibers on the back and / or front surface of the pile fabric within a range that does not impair the effects of the present invention.

  The organic-modified silicone-based softener is preferably an amino-modified silicone-based softener from the viewpoint of more effectively suppressing the hair loss of pile fibers while increasing the flexibility of the pile fabric. The amino-modified silicone softener is not particularly limited, and a solution in which an amino-modified polysiloxane used as a general fiber softening agent and dispersed by a method such as emulsification can be used. The amino-modified polysiloxane used here may have an amino functional group attached to one end or both ends of polysiloxane having a main chain, may have a side chain, or may have both a terminal and a side chain. . The structure of the amino functional group is not particularly limited, and examples thereof include a monoamine type, a diamine type, a triamine type, and a polyamine type. The amino-modified silicone softener is not particularly limited. For example, “Matsumoto Silicon Softener N-20” manufactured by Matsumoto Yushi Seiyaku Co., Ltd., “POLON-MF-14” manufactured by Shin-Etsu Chemical Co., Ltd., Momentive Performance A commercially available product such as "TSF4702" manufactured by Materials Japan GK can be used.

  In a pile fabric in which at least a part of the pile fibers disposed outside the ground yarn of the pile fibers on the back surface of the pile fabric are fused, generally, an acrylate ester resin or the like used for back coating of the pile fabric is used. The backing resin is attached to the back surface of the pile fabric to increase the flexibility of the back surface of the pile fabric. In the present invention, however, the pile fibers on the back surface of the pile fabric are made of an organic-modified silicone such as an amino-modified silicone-based softener. By adhering the system softener, the flexibility of the pile fabric can be increased without adhering the backing resin to the back surface of the pile fabric. Also, by attaching an organic-modified silicone-based softening agent to the pile fibers on the back surface of the pile fabric without adhering the backing resin to the back surface of the pile fabric, the tactile sensation (flexibility, low friction) of the back surface of the pile fabric is improved. Become.

  The pile fibers on the back side of the pile fabric may have the organic-modified silicone-based softener adhered thereto in an amount of 0.4 parts by weight or more based on 100 parts by weight of the pile fibers. The amount of the organic-modified silicone-based softener to be attached is preferably 0.4 to 2.5 parts by weight, more preferably 0.4 to 2.0 parts by weight, and more preferably 0.4 to 2.0 parts by weight. More preferably, it is 4 to 1.5 parts by weight. When the amount of the organic-modified silicone-based softener is within the above range, the pile fibers can be more effectively prevented from coming off while enhancing the flexibility of the pile fabric. The adhesion amount of an organic-modified silicone-based softener such as an amino-modified silicone-based softener on pile fibers can be determined by, for example, X-ray fluorescence analysis. For example, the adhesion amount of the amino-modified silicone-based softener can be calculated from a calibration curve by quantifying the Si element by X-ray fluorescence analysis using a wavelength-dispersive X-ray fluorescence analyzer. Specifically, using an X-ray fluorescence analyzer RIX3100 (manufactured by Rigaku Corporation), a Rh bulb (tube current 50 mA-tube voltage 50 kV), measurement diameter 30 mmφ, spectral crystal pentaerythritol (PET), 2θ angle 106 The Si element is analyzed under the condition of ~ 112 °, and first, a calibration curve is prepared using a sample having a known content of the amino-modified silicone softener. Next, a Si (Si) element was measured on a measurement sample (thickness: 3 mm, diameter: 30 mm) obtained by press-forming a measurement target fiber such as a portion (pile fiber) other than ground yarn on the back of the pile fabric by a press (tablet molding machine). Perform an analysis. By substituting the obtained Si detection counts into the calibration curve equation, it is possible to calculate the adhesion amount of the amino-modified silicone softener.

  Note that a backing resin can be used as long as the effects of the present invention are not impaired. As the backing resin, those generally used for back coating of a pile fabric may be used, and there is no particular limitation. For example, an acrylate resin, a polyurethane resin, or the like can be used. When the backing resin is used, it is preferable to impregnate the back surface of the pile fabric before the thermocompression bonding step in the pile fabric manufacturing method described later. The backing resin can be impregnated using a latex, emulsion, dispersion, or the like of a resin such as an acrylate resin or a polyurethane resin. The backing resin may be used alone or in combination of two or more.

  Hereinafter, the pile fabric of the present invention will be described with reference to the drawings. FIG. 1 is a schematic diagram illustrating a positional relationship between ground yarns and pile fibers entangled in the ground yarns in a high pile fabric according to an embodiment of the pile fabric of the present invention. As shown in FIG. 1, the high pile fabric 5 is formed into a knitted loop 6 and a loop 6 of the ground yarn 1, which is entangled with the surface 7 of a ground structure (high pile cloth 5) to form the nap pile 3. The pile fibers 2 are formed. Further, on the back surface 8 of the ground structure (high pile cloth 5), at least a part of the pile fibers 2 arranged outside the ground yarn 1 is thermocompression-bonded to form a thermocompression-bonded portion 4, which is thermocompressed to the ground yarn 1. Have been. The organically modified silicone softener adhering to the back surface of the pile fabric is omitted. FIG. 1 schematically shows a positional relationship in which the pile fibers 2 are superimposed on the underside of the ground yarn 1, but in FIG. Means the side part.

  Hereinafter, the method for producing the pile fabric of the present invention will be described.

  First, a pile fiber containing at least one fiber selected from the group consisting of acrylic fiber and acrylic fiber, and a ground yarn having a softening point higher than that of the pile fiber are used, and a ground structure and the ground structure are formed by a conventional method. A pile fabric containing pile fibers entangled with the ground yarn to be formed and raised on the surface of the ground structure is produced. The pile fibers are preferably composed of acrylic fibers and / or acrylic fibers. In this step, when a pile fiber to which an organic-modified silicone-based softener is attached is used as the pile fiber, an organic-modified silicone-based softener such as the amino-modified silicone-based softener is attached to the back surface of the pile fabric described later. The step of performing the treatment may be omitted, or an organically modified silicone softener may be further applied. The method for attaching an organically modified silicone-based softener such as an amino-modified silicone-based softener to pile fibers is not particularly limited, and a known method may be appropriately employed. For example, the pile fibers may be immersed in an organically modified silicone softener, or the pile fibers may be spray-coated with an organically modified silicone softener. Due to the simplicity of the process, the attachment of the organically modified silicone softener to the pile fiber can be performed simultaneously with the dyeing. Of course, the dyeing may be performed in a separate step from the dyeing. However, when the dyeing is performed in a separate step, it is preferable to attach an organically modified silicone softener after the dyeing step from the viewpoint of improving the flexibility of the pile fabric. The organically modified silicone-based softener may be used alone or in combination of two or more. As a raw material of the pile fabric, a fiber to which a commercially available organic-modified silicone-based softener (such as an amino-modified silicone-based softener) may be used. When a fiber to which a commercially available organic-modified silicone-based softener is attached is used as the pile fiber, the organic-modified silicone-based softener may be further attached to the fiber before the pile fabric is manufactured.

  Next, an organically modified silicone-based softener such as the amino-modified silicone-based softener is adhered to the back surface of the pile fabric. As a result, on the back surface of the pile fabric, the organic-modified silicone-based softener is attached to the pile fibers. The method of attaching the organic-modified silicone softener such as the amino-modified silicone softener to the back surface of the pile fabric is not particularly limited, and a known method may be appropriately employed. For example, the back surface of the pile fabric may be impregnated with an organic-modified silicone-based softener, or the back surface of the pile fabric may be spray-coated with the organic-modified silicone-based softener. The organically modified silicone-based softener may be used alone or in combination of two or more.

  The softening agent usually imparts flexibility and slipperiness to the surface of the fiber, but in the present application, surprisingly, at least one fiber selected from the group consisting of acrylic fiber and acrylic fiber is taken as pile fiber, In a pile fabric for fusing at least a portion of pile fibers among pile fibers arranged on the back side of the pile fiber on the back surface of the pile fiber, the pile fibers on the back surface of the pile fabric are coated with the above-mentioned organic modified silicone softener. By adhering 0.4 parts by weight or more to 100 parts by weight of the pile fiber, the flexibility of the pile fabric can be improved and the hair loss of the pile fiber can be suppressed. Although the reason is not clear, an organically modified silicone-based softening agent is attached to the pile fibers on the back surface of the pile fabric, and as described later, the back surface side of the pile fabric constitutes the softening point of the pile fiber or more and the ground structure. It is presumed that the thermocompression bonding at a temperature lower than the softening point of the fibers to be performed crosslinks functional groups such as terminal amino groups in the organically modified silicone softener adhering to the pile fibers on the back surface of the pile fabric. Is done. From the viewpoint of improving the flexibility of the pile fabric and more effectively suppressing hair loss of pile fibers, pile fibers or organically modified silicone-based softeners to which no organic-modified silicone-based softener is attached are attached. After producing a pile fabric using pile fibers, it is preferable to attach an organically modified silicone-based softening agent to the back side of the pile fabric.

  Next, the back side of the pile fabric is thermocompression-bonded at a temperature equal to or higher than the softening point of the pile fibers and lower than the softening point of the fibers constituting the ground structure. Thereby, pile fibers which are raised on the surface of the ground structure are not fused, and a part or all of the pile fibers arranged outside the ground yarns constituting the ground structure on the back surface of the ground structure are fused. Let it. The thermocompression bonding can be performed, for example, by arranging the pile fabric so that the back surface is in contact with a heating roll or a hot plate, and pressurizing the pile fabric with a rubber roll or the like. When a heating roll or a hot plate is used, a short-time thermocompression treatment can be performed, and at least a portion of the pile fibers arranged outside the ground yarn can be thermocompressed on the back surface of the ground structure. Then, the heating is not performed so that the pile fibers on the surface of the pile fabric are melted, so that the pile fibers raised on the surface of the ground structure are not melted.

  It is preferable to cool the pile fibers which are raised on the surface of the pile fabric when performing the thermocompression treatment from the back side of the pile fabric and / or after the thermocompression treatment. Further, it is preferable to cool the back side of the pile fabric after the thermocompression treatment from the back side of the pile fabric. As the cooling means, it is preferable to cool the surface and / or the back surface of the pile fabric with a cooling roll through which water having a water temperature of 50 ° C. or less is passed. The temperature of the water passed through the cooling roll is preferably from 10 to 40 ° C, more preferably from 10 to 35 ° C, and still more preferably from 15 to 30 ° C, from the viewpoint of cooling efficiency and productivity. By performing such cooling, the dimensional stability of the pile fabric can be maintained, and thermal damage to the pile fibers can be reduced.

  The thermocompression bonding process in an example of the pile fabric manufacturing method of the present invention will be described in more detail with reference to the drawings.

FIG. 2 is a manufacturing process diagram schematically showing a process of performing thermocompression bonding of a pile fabric from a back surface at a predetermined temperature. The processing apparatus 10 used for the thermocompression bonding process, specifically, the thermocompression bonding process, includes a heating roll 11 coated with a fluororesin such as polytetrafluoroethylene, and a heating roll 11, which is pressurized. A cooling rubber roll 12 through which water flows, a metal cooling roll 13 which pressurizes the cooling rubber roll 12 and through which cooling water of 30 ° C. flows, a metal cooling roll 14 through which cooling water of 30 ° C. flows, and a guide roll 15 inclusive. The pile fabric raw material (high pile fabric with an organically modified silicone softener) 18 is led out of the container 16, the back surface 18 b contacts the heating roll 11, and the front surface (upright pile side) 18 a contacts the cooling rubber roll 12. Supply as follows. After the thermocompression bonding, the back surface 18 b is cooled by the metal cooling roll 14. The pile fabric 19 that has been processed is stored in the container 17. Note that the thermocompression bonding process is not limited to the processing apparatus illustrated in FIG. 2, and may be performed using an apparatus in which a part of the processing apparatus illustrated in FIG. 2 is modified, a hot plate, and another apparatus. . For example, a rubber roll that does not cool can be used instead of the cooling rubber roll 12, and the metal cooling roll 13 may be omitted. In the thermocompression bonding, the heating temperature may be at least the softening point of the pile fiber and less than the softening point of the fibers constituting the ground yarn, and the pressing force may be 0.01 to 100 kgf / cm ² (0.98 KPa to 9) at a linear pressure. .8 MPa), the feed rate of the raw material is preferably 0.1 to 20 m / min, and the contact time of the heater (such as a heating roll) is preferably 1 to 60 seconds. In addition, from the viewpoint of reducing damage to the surface of the pile fabric, the pressure is 2.0 to 50 Kgf / cm ² (0.20 to 4.9 MPa) in linear pressure, and the heater contact time is 1 to 10 seconds. Is more preferred.

  In the case of a high pile fabric, since the high pile fabric shrinks in the wale direction during the thermocompression treatment, it may be stretched in the wale direction after the thermocompression treatment.

As the stretching treatment, it is preferable to hold both side ends (cloth ears) of the high pile fabric in the wale direction and to stretch in the wale direction so that the stretching ratio of the length in the wale direction is about 5 to 20%. It is preferably about 7 to 15%, and more preferably about 8 to 12%. The stretching ratio of the length in the wale direction is represented by the following equation.
Stretching ratio (%) of length in the wale direction = {(length in the wale direction after stretching−length in the wale direction before stretching) / length in the wale direction before stretching} × 100

  When heating is performed during the stretching treatment, the stretching treatment is preferably performed at 90 to 150 ° C, more preferably 100 to 130 ° C, and still more preferably 105 to 120 ° C.

  Such a stretching process can be performed using a known device such as a tenter. The tenter is generally used to heat set at a predetermined temperature while holding both cloth ears of the cloth to widen the cloth to a predetermined width and heat-set. As described above, heating may or may not be performed. In the tenter, there are a clip tenter method and a pin tenter method as a method for holding the fabric lugs, and any of these methods may be employed. From the viewpoint of process stability and / or productivity, the pin tenter method is employed. Is preferred.

  In the case where the stretching treatment is performed while heating the high pile fabric, it is preferable to perform the stretching at a minimum temperature and a minimum air flow so as not to damage the surface of the high pile fabric.

In the pile fabric of the present invention, hair loss is suppressed, and the average hair loss amount measured by the method described below is preferably 4.0 g / m ² or less, and preferably 3.0 g / m ² or less. More preferably, it is even more preferably 2.0 g / m ² or less. Further, the maximum amount of hair detachment measured by the method described below is preferably 5.0 g / m ² or less, more preferably 4.0 g / m ² or less, and more preferably 3.0 g / m ² or less. Is more preferred.

  In the pile fabric of the present invention, from the viewpoint of excellent flexibility, the 90 ° distance measured by the method described below is preferably 50 mm or less, and more preferably 45 mm or less.

  Hereinafter, the present invention will be described more specifically with reference to examples. In addition, this invention is not limited to a following example.

<Measurement method>
1. As shown in FIG. 3, the pile fabric 21 (length 280 mm, width 210 mm) is placed on the slope of the metal plate 22 which is arranged obliquely so that the angle a of the slope is 30 °. An adhesive tape 23 (Scotch No. 850, manufactured by 3M, 25 mm width) cut to a length of 100 mm is placed on the surface of the pile cloth 21 and is arranged to face upward. After a load of cm ² was applied for 1 minute (not shown), the adhesive tape 23 was continuously peeled from the pile fabric 21 from the end located on the upper slope. The weight (g) of the hair attached to the pressure-sensitive adhesive tape was measured, and the weight of the hair per area of the pressure-sensitive adhesive tape (g / m ² ) was calculated, which was defined as the amount of hair loss. The amount of hair loss at any three places of the pile fabric was measured and calculated as described above, and the average amount of hair loss and the maximum amount of hair loss were obtained.

2. Hair loss evaluation Based on the amount of hair loss, the hair loss was evaluated in four ranks as follows. The S, A, and B evaluations were accepted, and the C evaluation was rejected.
S: The average amount of hair loss is 2.0 g / m ² or less, and the maximum amount of hair loss is 3.0 g / m ² or less.
A: The average hair loss is more than 2.0 g / m ^{2 and} 3.0 g / m ² or less, and the maximum hair loss is more than 3.0 g / m ^{2 and} 4.0 g / m ² or less.
B: The average hair loss amount is more than 3.0 g / m ^{2 and} 4.0 g / m ² or less, and the maximum hair loss amount is more than 4.0 g / m ^{2 and} 5.0 g / m ² or less.
C: The average amount of hair loss exceeds 4.0 g / m ² , and the maximum amount of hair loss exceeds 5.0 g / m ² . (Fail level)

(Flexibility of pile fabric)
(1) The pile fabric was cut in the vertical direction to a width of 20 mm to obtain a piece of fabric having a length of 200 mm and a width of 20 mm.
(2) As shown in FIG. 4A, a piece 31 of pile fabric was placed on a horizontal table 32 (600 mm wide, 600 mm long) made of melamine resin. Next, the fabric piece 31 of the pile fabric was slid little by little from the horizontal platform 32 to the outside of the horizontal platform 32 along the fur direction of the pile fabric.
(3) As shown in FIG. 4B, until the angle a between the tangent 41 drawn on the tip of the piece 31 of pile fabric that has come out of the horizontal base 32 and the horizontal base 32 becomes 90 °. The fabric piece 31 of the pile fabric was slid.
(4) The distance L (90 ° distance) in which the cloth piece 31 of the pile cloth was slid from the horizontal table 32 was measured, and the flexibility was evaluated based on the following criteria.
A: 90 ° distance is less than 50 mm (pile fabric is considerably soft)
B: 90 ° distance is 50 mm or more and 55 mm or less (pile fabric is soft)
C: 90 ° distance exceeds 55 mm (pile cloth is hard)

<Fiber>
1. Pile fiber (1) Trade name “Kanecaron (registered trademark) ELP” (manufactured by Kaneka Corporation): acrylic fiber (vinyl chloride-acrylonitrile fiber), softening point 180 to 190 ° C., fineness 27 dtex, cut length 102 mm (in the following) , Simply referred to as ELP.), No adhesion of amino-modified silicone softener.
(2) Trade name “Kanecaron (registered trademark) AH” (manufactured by Kaneka Corporation): acrylic fiber (vinyl chloride-acrylonitrile fiber), softening point 180 to 190 ° C., fineness 7.8 dtex, cut length 76 mm (in the following) , Simply referred to as AH7.8), and 0.3 parts by weight of the amino-modified silicone-based softener adhered to 100 parts by weight of the fiber (analytical value obtained by X-ray fluorescence analysis).
(3) Trade name “Kanecaron (registered trademark) AH” (manufactured by Kaneka Corporation): Acrylic fiber (vinyl chloride-acrylonitrile fiber), softening point 180-190 ° C., fineness 5.6 dtex, cut length 51 mm (below) , Simply referred to as AH5.6), and 0.3 parts by weight of the amino-modified silicone-based softener adhered to 100 parts by weight of the fiber (analytical value obtained from X-ray fluorescence analysis).
(4) Trade name “Kanecaron (registered trademark) MCS” manufactured by Kaneka Corporation): acrylic fiber (vinyl chloride-acrylonitrile fiber), softening point 180 to 190 ° C, fineness 4.4 dtex, cut length 32 mm (hereinafter, Simply referred to as MCS.), No adhesion of amino-modified silicone softener.
In the above description, the amount of the amino-modified silicone-based softening agent attached to the acrylic fiber is calculated by a calibration curve by quantifying the Si element by X-ray fluorescence analysis using a wavelength-dispersive X-ray fluorescence analyzer. did. Specifically, using an X-ray fluorescence analyzer RIX3100 (manufactured by Rigaku Corporation), a Rh bulb (tube current 50 mA-tube voltage 50 kV), measurement diameter 30 mmφ, spectral crystal pentaerythritol (PET), 2θ angle 106 The Si element was analyzed under the condition of ~ 112 °, and a calibration curve was first prepared using a sample having a known content of the amino-modified silicone softener. Next, Si elements were analyzed using a measurement sample (thickness: 3 mm, diameter: 30 mm) obtained by press-molding the measurement target fiber with a press (tablet molding machine). By substituting the obtained Si detection counts into the calibration curve equation, the amount of the amino-modified silicone-based softener was calculated.
2. Ground structure constituent fiber (ground yarn)
A multifilament having a total fineness of 334 dtex (a fiber yarn in which two filaments having a fineness of 167 dtex composed of 50 polyester monofilaments were aligned) was used. The softening point is 258 ° C.
The above-mentioned softening point of the fiber is determined by opening 1 g of the fiber, placing the fiber on a hot plate heated to an arbitrary temperature, and pressing with a pressure roll at a pressure (nip pressure) of 0.07 kgf / cm ² for 3 seconds. This is the temperature at which the single fibers on the surface in contact with the hot plate are softened and combined into a plate shape.

(Example 1)
Using a sliver knitting machine (circular knitting machine) for producing fake fur, using the above polyester fiber yarn as ground yarn, ELP, AH7.8 and AH5.6, ELP / AH7.8 / AH5. A pile fiber sliver (10 to 14 g) uniformly mixed at a mixing ratio of 6 = 15/35/50 (% by weight) was supplied, and a high pile fabric was knitted. The number of loops in the wale of the ground structure was 16 to 17 / inch, and the number of loops in the course was 22 to 33 / inch. Next, pile fibers on the raised surface of the high pile fabric were prepared by polishing and shearing. Specifically, polishing was first performed twice at 120 ° C., and then shearing was performed twice.

  The amino-modified silicone-based softener (solid content) is attached to the back surface of the high pile fabric obtained above so that 0.2 parts by weight of the amino-modified silicone-based softener (solid content) adheres to 100 parts by weight of the pile fibers on the back surface side. An aqueous solution of “Matsumoto Silicon Softener N-20” (trade name, manufactured by Matsumoto Yushi-Seiyaku Co., Ltd., solid content: 20% by weight) was spray-coated. Thereafter, using a pin tenter dryer, the high-pile cloth was dried for 3 minutes at a temperature in the dryer of 125 ° C. while stretching the width to 160 cm, and cooled to 80 ° C. or lower while maintaining the width at 160 cm.

The temperature of the heating roll was 215 ° C., the contact time between the heating roll and the high pile fabric was 3 seconds using the thermocompression bonding apparatus shown in FIG. 2 on the back surface of the high pile fabric (width 160 cm) obtained above, The thermocompression bonding was performed under the condition that the nip pressure of the cooling rubber roll was 50 kgf / cm ² (4.9 MPa). At that time, the fabric width of the high pile fabric shrank to 135 cm. Thereafter, using a pin tenter dryer, the high-pile cloth was dried for 3 minutes at a temperature in the dryer of 125 ° C. while stretching the width to 160 cm, and cooled to 80 ° C. or lower while maintaining the width at 160 cm.

In the obtained high pile fabric, pile fibers on the surface of the pile fabric were prepared by polishing, brushing and shearing. Specifically, brushing is first performed twice, followed by polishing once each at 155 ° C., 150 ° C., 145 ° C., 130 ° C., and 120 ° C., and thereafter, shearing is performed twice, and finally at 100 ° C. Polishing was performed twice. Finally, a high pile fabric having a basis weight of 700 g / m ² and a pile fiber length of the raised portion of 20 mm was obtained.

(Example 2)
An aqueous solution of an amino-modified silicone-based softener was spray-coated on the back of the pile fabric such that 1 part by weight of the amino-modified silicone-based softener (solid content) adhered to 100 parts by weight of the pile fiber on the back of the pile fabric. In the same manner as in Example 1, a high pile fabric was produced.

(Comparative Example 1)
In the same manner as in Example 1 except that an unmodified silicone softener (manufactured by Matsumoto Yushi Seiyaku Co., Ltd., trade name “dimethyl silicone K”, solid content 20% by weight) was used instead of the amino-modified silicone softener. Thus, a high pile fabric was produced.

(Comparative Example 2)
In the same manner as in Example 2 except that an unmodified silicone softener (manufactured by Matsumoto Yushi Seiyaku Co., Ltd., trade name “dimethyl silicone K”, solid content 20% by weight) was used instead of the amino-modified silicone softener. Thus, a high pile fabric was produced.

(Comparative Example 3)
Instead of using an amino-modified silicone-based softener, a fatty acid-based softener ("PK-608" manufactured by Yancheng jiaye textile materials co., LTD., Solid content 20% by weight) was used. In the same manner as in Example 1, a high pile fabric was produced.

(Comparative Example 4)
Instead of using an amino-modified silicone-based softener, a fatty acid-based softener ("PK-608" manufactured by Yancheng jiaye textile materials co., LTD., Solid content 20% by weight) was used. In the same manner as in Example 2, a high pile fabric was produced.

(Comparative Example 5)
A high pile fabric was produced in the same manner as in Example 1 except that the thermocompression treatment was performed without attaching a softening agent to the pile fibers on the back surface of the pile fabric.

(Comparative Example 6)
A high pile fabric was produced in the same manner as in Example 1, except that a sliver (10 to 14 g) composed of 100% by weight of AH7.8 was used as the pile fiber sliver.

(Comparative Example 7)
A high pile was prepared in the same manner as in Example 1 except that a sliver (10 to 14 g) obtained by uniformly mixing ELP and MCS at a mixing ratio of ELP / MCS = 20/80 (wt%) was used as the pile fiber sliver. A fabric was made.

The hair removal and flexibility of the high pile fabrics obtained in Examples 1 and 2 and Comparative Examples 1 to 7 were measured and evaluated by the methods described above. The results are shown in Table 1 below. In Table 1 below, the attached amount of the softener is the weight ratio of the softener to 100 parts by weight of the pile fiber on the back surface of the pile fabric. Specifically, in Example 1, the amount of the softener attached was determined by the amount of the softener attached to the fiber used as the raw material of the pile fiber and the amount of the softener added to the pile fiber on the back surface of the pile fabric in the pile fabric manufacturing process. It is the total amount of the attached softeners of the same type attached and was calculated as follows. In Example 2 and Comparative Examples 1 to 7, the adhesion amounts of various softeners were calculated in the same manner as in Example 1.
Example 1 Amino-Modified Silicone Softener Attached to 100 Parts by Weight of Fiber Used as Pile Fiber Raw Material = AH7.8 and AH5.6 Derived = 3 (parts by weight) × 85 (% by weight) = 0. 255 parts by weight Additional amount of amino-modified silicone-based softener adhered to 100 parts by weight of pile fiber on the back side of pile fabric in the manufacturing process of pile fabric = 0.2 part by weight 100 parts by weight of pile fiber on back side of pile fabric Amount of amino-modified silicone-based softening agent to the resin = 0.255 + 0.2 (parts by weight) = 0.455 parts by weight

  As can be seen from the results in Table 1 above, the amino-modified silicone-based softener adhered to the pile fibers on the back surface of the pile fabric in an amount of 0.4 parts by weight or more based on 100 parts by weight of the pile fibers. The pile fabric had high flexibility of the pile fabric, and the hair loss of the pile fiber was suppressed.

  On the other hand, the total amount of the amino-modified silicone-based softener and the unmodified silicone-based softener attached to the pile fibers on the back surface of the pile fabric is 0.4 parts by weight or more with respect to 100 parts by weight of the pile fibers. The pile fabrics of Comparative Examples 1 and 2 in which the amount of the amino-modified silicone-based softening agent adhered to the pile fibers of 100 parts by weight was less than 0.4 parts by weight, although the pile fabrics had good flexibility, but the pile fibers had hair loss. The amount was large. The total amount of the amino-modified silicone-based softener and fatty acid-based softener adhered to the pile fibers on the back surface of the pile fabric is 0.4 parts by weight or more based on 100 parts by weight of the pile fibers. The pile fabrics of Comparative Examples 3 and 4, in which the amount of the amino-modified silicone-based softening agent adhered to 100 parts by weight was less than 0.4 part by weight, also had good flexibility of the pile fabric, but the amount of pile fibers coming off was low. There were many. Comparative Examples 5 and 6, wherein the amount of the amino-modified silicone-based softening agent adhering to the pile fibers on the back surface of the pile fabric was less than 0.4 parts by weight based on 100 parts by weight of the pile fibers, the back surface of the pile fabric. In the pile fabric of Comparative Example 7 in which the amino-modified silicone-based softening agent was not attached to the pile fiber in the above, the pile fabric was hard, though hair loss of the pile fiber was suppressed.

REFERENCE SIGNS LIST 1 ground yarn 2 pile fiber 3 nap pile 4 thermocompression bonding section 5 high pile fabric 6 loop 7 front surface 8 back surface 10 processing device 11 heating roll 12 cooling rubber roll 13, 14 metal cooling roll 15 guide roll 16, 17 container 18 pile fabric raw fabric 18a Pile fabric web surface 18b Pile fabric web back surface 19, 21 Pile fabric 22 Metal plate 23 Adhesive tape 31 Pile fabric piece 32 Horizontal table 41 Tangential line drawn at the tip of pile fabric piece

Claims (6)

Ground texture, including pile fibers entangled with the ground yarns constituting the ground texture and raising the surface of the ground texture, wherein the pile fibers include at least one fiber selected from the group consisting of acrylic fibers and acrylic fibers. In the pile fabric, the pile fiber has a lower softening point than the fiber constituting the ground structure,
Of the pile fibers entangled with the ground yarns constituting the ground structure, pile fibers raised on the surface of the ground structure are not fused, and the back surface of the ground structure is outside the ground yarns forming the ground structure. At least a part of the pile fibers arranged in is fused,
The pile fibers on the back side of the pile fabric may include, for 100 parts by weight of the pile fibers, at least one organic compound selected from the group consisting of an amino-modified silicone-based softener, an epoxy-modified silicone-based softener, and a carboxyl-modified silicone-based softener. A pile fabric, wherein 0.4 part by weight or more of the modified silicone softener is adhered.   The pile fabric according to claim 1, wherein the organic-modified silicone-based softener is an amino-modified silicone-based softener.   The pile fabric according to claim 1, wherein the pile fiber is an acrylic fiber.   The pile fabric according to any one of claims 1 to 3, wherein the ground yarn is a polyester fiber yarn.   The pile according to any one of claims 1 to 4, wherein 0.4 to 2.5 parts by weight of the organic modified silicone softener is adhered to 100 parts by weight of pile fibers on the back surface of the pile fabric. Fabric. It is a manufacturing method of the pile cloth according to any one of claims 1 to 5,
Ground texture, including pile fibers entangled with the ground yarns constituting the ground texture and raising the surface of the ground texture, wherein the pile fibers include at least one fiber selected from the group consisting of acrylic fibers and acrylic fibers. In the pile fabric, the pile fiber has a lower softening point than the fiber constituting the ground structure,
The pile fibers on the back side of the pile fabric may include, for 100 parts by weight of the pile fibers, at least one organic compound selected from the group consisting of an amino-modified silicone-based softener, an epoxy-modified silicone-based softener, and a carboxyl-modified silicone-based softener. 0.4 parts by weight or more of the modified silicone softener is attached,
By thermocompression bonding the back side of the pile fabric at a temperature equal to or higher than the softening point of the pile fibers and lower than the softening point of the fibers constituting the ground structure, of the pile fibers entangled with the ground yarns forming the ground structure Pile fibers raised on the surface of the ground structure are not fused, and at least a part of the pile fibers arranged outside the ground yarns constituting the ground structure on the back surface of the ground structure is fused. A method for producing a pile fabric, which is characterized in that:

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