JP7549856B2 - Slip-resistant pile fabric and its manufacturing method - Google Patents

Description

The present invention relates to a pile fabric having a base fabric woven with warp and weft yarns and pile yarns attached to the weft yarns of the base fabric, and to a method for manufacturing the same.

Conventionally, a pile fabric for use in tile carpets has been known in which a backing layer is laminated to a multi-cross pile having three or more crosses, with a base warp thread, at least two finishing warp threads, and a plurality of pile warp threads as unit warps, and at least three weft threads as unit wefts (Patent Document 1).
In this pile fabric, the weft threads constituting the unit weft are partitioned into upper and lower layers by the pile warp submerged threads and ground warp threads, and are stratified into three layers: an upper layer between the pile layer and the submerged threads, a middle layer between the submerged threads and ground warp threads, and a lower layer behind the ground warp threads. The lower layer weft threads and ground warp threads are partitioned by the middle layer weft thread and pulled away from the submerged threads, so that they do not come into direct contact with the submerged threads, and the submerged threads are positioned deep in the base fabric biased toward the pile layer side.

JP 2004-27448 A

However, as described in paragraph 0011 of the patent, the pile fabric described in Patent Document 1 has weft threads that run straight in the width (weft) direction to ensure dimensional stability, so there is a risk that the pile warp threads that are held by the weft threads may slip in the weft direction, causing the pile warp threads to shift along the weft threads (causing misalignment).

In view of these circumstances, the present invention aims to provide a pile fabric and a manufacturing method thereof that can "suppress slippage and misalignment" by using filament yarn with crimped or wavy weft yarns.

The pile fabric 1 according to the present invention is a pile fabric for puffs, in which pile yarns 3 are woven into a base fabric 2, the base fabric 2 is woven with warp yarns 4 and weft yarns 5, the pile yarns 3 are engaged with the weft yarns 5 of the base fabric 2, the weft yarns 5 are multifilament yarns having crimps and/or undulations, and the single fiber fineness of the weft yarns 5 is 1.67d or more and 2.5d or less .
A second feature of the pile fabric 1 according to the present invention is that the pile fabric 1 is a pile fabric having pile yarns 3 woven into a base fabric 2, the base fabric 2 is woven with warp yarns 4 and weft yarns 5, the pile yarns 3 are engaged with the weft yarns 5 of the base fabric 2, the warp yarns 4 are filament yarns not formed with crimps and/or undulations, the weft yarns 5 are multifilament yarns formed with crimps and/or undulations, and the single fiber fineness of the weft yarns 5 is 1.67d or more and 2.5d or less.

A third feature of the pile fabric 1 according to the present invention is that the pile fabric 1 is a pile fabric in which pile yarns 3 are woven into a base fabric 2, the base fabric 2 is woven with warp yarns 4 and weft yarns 5, the pile yarns 3 are engaged with the weft yarns 5 of the base fabric 2, the warp yarns 4 are filament yarns not formed with crimps and/or undulations, and the weft yarns 5 are spun yarns.

A fourth feature of the pile fabric 1 according to the present invention is that the pile fabric 1 has dimensional stability and is formed by weaving pile yarns 3 into a base fabric 2, the base fabric 2 being woven with warp yarns 4 and weft yarns 5, the pile yarns 3 being engaged with the weft yarns 5 of the base fabric 2, the shrinkage ratio of the weft yarns 5 being greater than that of the warp yarns 4, and the shrinkage ratio of the weft yarns 5 being determined by the following: a certain length L15 in the weft direction of the pile fabric approximately along the longitudinal direction 5L of the weft yarns 5 in the pile fabric, a length L25 of the weft yarns 5 themselves woven into the pile fabric and corresponding to the certain length L15 in the weft direction of the pile fabric, and a certain length L25 of the weft yarns 5 itself in the weft direction of the pile fabric. The shrinkage ratio of the warp yarns 4 is determined by determining a difference ΔL5 between the length L15 and the warp yarn 4 in the warp direction of the pile fabric, and a ratio S5 of the difference ΔL5 to the constant length L15 in the weft direction of the pile fabric. The shrinkage ratio of the warp yarns 4 is determined by determining a constant length L14 in the warp direction of the pile fabric which is approximately along the longitudinal direction 4L of the warp yarns 4 in the pile fabric, a length L24 of the warp yarns 4 itself which is woven into the pile fabric and corresponds to the constant length L14 in the warp direction of the pile fabric, and a difference ΔL4 between the length L24 of the warp yarns 4 itself and the constant length L14 in the warp direction of the pile fabric, and a ratio S4 of the difference ΔL4 to the constant length L14 in the warp direction of the pile fabric .

A fifth feature of the pile fabric 1 according to the present invention, in addition to the above first to fourth features, is that each of the pile threads 3 passes under one weft thread 5 and is engaged with the single weft thread 5, and each of the pile threads 3 has a one-side pile piece portion 3A which protrudes from the base fabric 2 on one side of the single weft thread 5 after passing under the single weft thread 5, and an other-side pile piece portion 3B which protrudes from the base fabric 2 on the other side of the single weft thread 5 after passing under the single weft thread 5.

Alternatively, in the pile fabric 1, each of the pile yarns 3, with respect to three or more adjacent weft threads 5, may have a one-side pile piece portion 3A which passes under one or more weft threads 5 of the three or more adjacent weft threads 5, and then passes under another one or more weft threads 5 of the three or more adjacent weft threads 5 to be engaged therewith, and each of the pile yarns 3 may have a one-side pile piece portion 3A which passes under the most one-side weft thread 5a of the three or more adjacent weft threads 5 and then protrudes from the base fabric 2 on one side of the most one-side weft thread 5a, and an other-side pile piece portion 3B which passes under the other-side weft thread 5b of the three or more adjacent weft threads 5 and then protrudes from the base fabric 2 on the other side of the other-side weft thread 5b.

Due to these characteristics, by using a filament yarn with crimps and ripples for the weft yarn 5, unlike Patent Document 1, the pile yarn 3 that is engaged with the weft yarn 5 is less likely to slip (slip) in the weft direction due to the crimps and ripples formed at the engagement position relative to the weft yarn 5, and the shift (weave misalignment) of the pile yarn 3 along the weft yarn 5 is suppressed ("suppression of slippage and weave misalignment").

Furthermore, the weft yarn 5 may be a spun yarn, and unlike Patent Document 1, the presence of multiple fuzz on the surface can realize "suppression of slippage and misalignment".
The shrinkage rate of the weft yarn 5 may be set to be greater than that of the warp yarn 4.

Furthermore, by having one side pile piece portion 3A protruding from one side of a single weft yarn 5 underneath which each pile yarn 3 passes, and the other side pile piece portion 3B protruding from the other side, it is possible to "suppress slippage and misalignment" while also increasing the density of the pile yarn 3 ("higher pile yarn density").

And by having one-side pile piece portion 3A protruding from one side of the most one-side weft thread 5a of the three or more weft threads 5 through which each pile thread 3 passes, and the other-side pile piece portion 3B protruding from the other side of the most other-side weft thread 5b of the three or more weft threads 5, the pile thread 3 is more unlikely to slip at the hooking position with respect to the three or more weft threads 5, and misalignment is less likely to occur (further "suppression of slippage and misalignment" is realized), and each pile thread 3 is firmly woven into the base fabric 2, making each pile thread 3 less likely to come out of the base fabric 2 ("promotion of preventing pile threads from coming out").

The manufacturing method of the pile fabric 1 according to the present invention is a manufacturing method of a pile fabric in which pile yarns 3 are woven into a base fabric 2, the base fabric 2 is woven with warp yarns 4 and weft yarns 5, the pile yarns 3 are engaged with the weft yarns 5 of the base fabric 2 , the warp yarns 4 are filament yarns not formed with crimps and/or undulations, the weft yarns 5 are multifilament yarns, the weft yarns 5 being multifilament yarns are formed with crimps and/or undulations by false twisting and/or heat treatment , and the single fiber fineness of the weft yarns 5 is 1.67d or more and 2.5d or less .

Due to this feature, by forming shrinkage and undulations in the weft yarn 5, which is a filament yarn, through false twisting and heat treatment, unlike Patent Document 1, the position of the pile yarn 3 that is engaged with the weft yarn 5 relative to the weft yarn 5 is less likely to slip in the weft direction (less likely to slip) due to the shrinkage and undulations that have been formed through false twisting and heat treatment, and the shifting (weave misalignment) of the pile yarn 3 along the weft yarn 5 is suppressed ("suppression of slippage and weave misalignment").

The pile fabric and manufacturing method of the present invention can prevent slippage and misalignment by using filament yarn with crimped or wavy weft yarn.

1 is a photograph showing an example of a pile surface of a pile fabric according to the present invention; 1 is a photograph showing an example of a cross section of a pile fabric in the weft direction. 1 is a photograph showing an example of a warp cross section of a pile fabric. 1 is a photograph substituting a drawing illustrating the pile surface and the back surface of a pile fabric. FIG. 2 is a cross-sectional side view of a pile fabric in which a pile yarn is engaged with three or more weft yarns as viewed in the weft direction.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
<Overall configuration of pile fabric 1>
1 to 5 show an example of a pile fabric 1 according to an embodiment of the present invention.
The pile fabric 1 is a fabric having a base fabric 2 (described later) and a plurality of pile yarns 3 woven into the base fabric 2.

The pile fabric 1 may first be woven into two pile fabrics, each woven in a double layer above and below, and then the pile yarn 3 connecting them may be center-cut along a line (so-called center cut line) approximately in the center of the upper and lower pile fabrics 1 to divide them into two pile fabrics 1.
The thickness of the pile fabric 1 is the sum of the thickness of the base fabric 2 and the vertical length of the pile yarns 3 (pile length), and is not particularly limited, but may be, for example, 0.5 mm or more and 5.0 mm or less, preferably 0.7 mm or more and 4.5 mm or less, and more preferably 1.0 mm or more and 4.0 mm or less (2.0 mm or 2.2 mm).

<Base fabric 2>
As shown in Figs. 1 to 5, the base fabric 2 is formed by weaving warp threads 4, which will be described later, and weft threads 5, which will be described later (one side weft thread 5a, the other end side weft thread 5b, and intermediate weft thread 5m).
The structure (weave structure) of the base fabric 2 is not particularly limited, but for example, the warp threads 4 may be arranged side by side in the weaving width direction, and each warp thread 4 may pass under multiple weft threads 5 every time it passes over multiple weft threads 5 (this may also be called a twill weave structure).

Alternatively, each warp thread 4 may pass under one or more weft threads 5 for every one it passes over, and it can be said that the warp threads 4 and the weft threads 5 form a plain weave or a twill weave.
To explain this case in detail, each warp thread 4 may pass under one weft thread 5 every time it passes over one weft thread 5 (plain weave structure), or it may pass under two weft threads 5 every time it passes over one weft thread 5 (twill weave structure), or it may pass under three weft threads 5 every time it passes over one weft thread 5 (twill weave structure).

The thickness of the base fabric 2 is not particularly limited, but may be, for example, 0.01 mm or more and 1.00 mm or less, preferably 0.05 mm or more and 0.90 mm or less, and more preferably 0.10 mm or more and 0.80 mm or less (0.3 mm).
The width of the base fabric 2 is not particularly limited and may be, for example, 20 inches to 100 inches (e.g., 65 inches). Furthermore, the number of reeds of the loom that weaves the base fabric 2 and the pile yarns 3 is not particularly limited and may be, for example, 10 feathers/inch to 90 feathers/inch.
The warp threads 4 and weft threads 5 in the base fabric 2 will be described below.

<Warp thread 4 etc.>
As shown in Figures 1 to 5, the warp threads 4 are arranged along the weaving direction (one direction) of the woven base fabric 2 or along the longitudinal direction of the warp threads 4 (both directions, also called the warp direction) (in other words, they are arranged side by side in the weaving width direction).
The warp yarn 4 may be either a filament yarn (long fiber yarn) or a spun yarn (short fiber yarn, spun yarn). If it is a filament yarn, it may be a monofilament or multifilament, or it may be an unprocessed filament yarn (raw silk).
The total fineness of the warp yarns 4 is not particularly limited, but may be, for example, 20 d (denier) or more and 1500 d or less, preferably 50 d or more and 1000 d or less, and more preferably 100 d or more and 600 d or less (50 d/30 filaments, 50 d/20 filaments, etc.). The single fiber fineness of the warp yarns 4 is not particularly limited, but may be, for example, 0.1 d (denier) or more and 1500 d or less, preferably 0.5 d or more and 1000 d or less, and more preferably 1 d or more and 600 d or less.

The material of the warp threads 4 is also not particularly limited, and may be, for example, polyester fibers such as PET, cotton fibers, rayon fibers, nylon fibers, acetate fibers, twisted yarns thereof, or blended yarns thereof.
The number of warp threads 4 per inch is not particularly limited, and may be, for example, 10 to 30 (eg, 21).

<Weft thread 5, shrinkage, waviness>
As shown in Figures 1 to 5, the weft yarns 5 are arranged along the weaving width direction or the longitudinal direction 5L of the weft yarns 5 (also called the weft direction) of the woven base fabric 2 (in other words, they are arranged side by side in the weaving direction).
The weft yarn 5 may be a filament yarn (long fiber yarn) having crimp and/or ripple formed therein. In this case, the weft yarn 5 may be said to be a woolly processed yarn, and its configuration may be monofilament, multifilament, etc.

Here, the "crimp" in the present invention refers to a part of the weft yarn 5 that is curled (such as a part that is curled in a spiral shape), and is also called a crimp.
In the present invention, the "waviness" refers to a meandering portion of the weft yarn 5.

In addition, when the above-mentioned warp thread 4 is a filament thread, the warp thread 4 may have a crinkle or ripple formed therein, or the warp thread 4 may not have a crinkle or ripple formed therein (the warp thread 4 may be a filament thread (raw silk) that has not been processed in any way).
Here, in the case where the warp yarns 4, which are filament yarns, are not crimped or wavy, and only the weft yarns 5 are filament yarns that are crimped or wavy, it can be said that the pile fabric 1 can maintain the dimensional stability of the pile fabric 1 itself while also achieving "suppression of slippage and misalignment" of the pile yarns 3, which will be described later.

The weft yarn 5 may also be a spun yarn (staple fiber yarn, spun yarn).
In this case, even if the warp yarns 4 are spun yarns and only the weft yarns 5 are filament yarns in which shrinkage or undulation has been formed, it can be said that the pile fabric 1 can maintain the dimensional stability of the pile fabric 1 itself while also achieving "suppression of slippage and misalignment" of the pile yarns 3, which will be described later, in the same manner as described above.
The total fineness of the weft yarn 5 is not particularly limited, but may be, for example, 20d (denier) or more and 1500d or less, preferably 50d or more and 1000d or less, and more preferably 100d or more and 600d or less (50d/20 filaments, 50d/30 filaments, etc.), or may be a two-ply yarn (20/2) in which two single yarns of cotton count 20 are twisted together. The single fiber fineness of the weft yarn 5 is also not particularly limited, but may be, for example, 0.1d (denier) or more and 1500d or less, preferably 0.5d or more and 1000d or less, and more preferably 1d or more and 600d or less.

The material of the weft yarn 5 is also not particularly limited, and may be, for example, polyester fiber such as PET, cotton fiber, rayon fiber, nylon fiber, acetate fiber, twisted yarns thereof, or blended yarns thereof.
In addition, the number of weft yarns 5 (the number of weft yarns 5 woven per inch in the weaving direction) is not particularly limited, and may be, for example, 20 to 250, preferably 30 to 200, and more preferably 40 to 150 (130), etc.
Furthermore, the more weft yarns 5 are woven, the more pile yarns 3 are engaged with the weft yarns 5 per inch in the weaving direction, making it easier to sandwich the pile yarns 3 between adjacent weft yarns 5 and easier for adjacent pile yarns 3 to engage with each other.Furthermore, it can be said that this not only "suppresses slippage and misalignment," but also "promotes prevention of pile yarns coming off."

<Shrinkage ratio S>
The shrinkage ratios S of the weft yarn 5 and warp yarn 4 described above are not particularly limited. For example, the shrinkage ratio S5 of the weft yarn 5 may be larger than the shrinkage ratio S4 of the warp yarn 4.
Here, the "shrinkage ratio S5 of the weft yarn 5" in the present invention means a fixed length L15 in the weft direction of the pile fabric 1 approximately along the longitudinal direction 5L of the weft yarn 5 in the pile fabric 1 after it has been woven, a length L25 of the weft yarn 5 itself which is woven into the pile fabric 1 and corresponds to the fixed length L15 in the weft direction of the pile fabric 1, and a difference ΔL5 (=L25-L15) between the length L25 of the weft yarn 5 itself and the fixed length L15 in the weft direction of the pile fabric 1, and a ratio S5 (=100×ΔL5/L15) of this difference ΔL5 to the fixed length L15 in the weft direction of the pile fabric 1.

In addition, the "shrinkage ratio S4 of the warp threads 4" in the present invention means a fixed length L14 in the warp direction of the pile fabric 1 approximately aligned with the longitudinal direction 4L of the warp threads 4 in the pile fabric 1 after it has been woven, a length L24 of the warp threads 4 themselves which are woven into the pile fabric 1 and correspond to the fixed length L14 in the warp direction of the pile fabric 1, and a difference ΔL4 (= L24 - L14) between the length L24 of the warp threads 4 themselves and the fixed length L14 in the warp direction of the pile fabric 1, and a ratio S4 (= 100 × ΔL4/L14) of this difference ΔL4 to the fixed length L14 in the warp direction of the pile fabric 1.
It can be said that even when the shrinkage ratio S5 of the weft yarn 5 is greater than the shrinkage ratio S4 of the warp yarn 4 (S5>S4), the pile fabric 1 can maintain the dimensional stability of the pile fabric 1 itself while suppressing slippage and misalignment of the pile yarns 3, which will be described later.
Furthermore, when the shrinkage ratio S5 of the weft yarn 5 is greater than the shrinkage ratio S4 of the warp yarn 4, the difference ΔS between the shrinkage ratio S5 of the weft yarn 5 and the shrinkage ratio S4 of the warp yarn 4 is not particularly limited, but may be, for example, greater than 5% and less than 90%, preferably greater than 10% and less than 70%, and more preferably greater than 15% and less than 50%.

The pile yarns 3, which will be described later, are held to such weft yarns 5. The number of weft yarns 5 to which the pile yarns 3 are held is not particularly limited. For example, each pile yarn 3 may be held to one weft yarn 5 or to three or more adjacent weft yarns 5.
Various types of weft yarns 3 in which the pile yarn 3 is held by three or more adjacent weft yarns 5 will be described below.

<Various weft yarns 5 in the case where the pile yarn 3 is engaged with three or more weft yarns 5>
As shown in Figures 1 to 5 (particularly Figure 5), the weft thread 5 may have any configuration as long as it is woven with the warp thread 4 to form the base fabric 2. For example, the weft thread 5 may have one side weft thread 5a and the other side weft thread 5b, and an intermediate weft thread 5m between the one side weft thread 5a and the other side weft thread 5b, and these weft threads 5a, 5b, and 5m may be arranged side by side in the weaving direction.
Here, the one side weft 5a is the weft 5 that is located on the furthest side of the three or more adjacent (front and back) weft threads 5 in the longitudinal direction 4L of the warp thread 4 and is woven below or above the warp thread 4, the other side weft 5b is the weft 5 that is located on the rearmost side of the three or more adjacent (front and back) weft threads 5 in the longitudinal direction 4L of the warp thread 4 and is woven above or below the warp thread 4, and the intermediate weft 5m is the weft 5 other than the one side weft 5a and the other side weft 5b mentioned above (the weft 5 between the one side weft 5a and the other side weft 5b) among the three or more adjacent (front and back) weft threads 5 in the longitudinal direction 4L of the warp thread 4.

The one side weft 5a, the other side weft 5b, and the intermediate weft 5m may all have approximately the same fineness (total fineness), or at least two of them may be different from each other. Furthermore, the one side weft 5a, the other side weft 5b, and the intermediate weft 5m may be made of the same material, or at least two of them may be different from each other.
In addition, for each of the weft threads 5a, 5b, 5m, a plurality of pile threads 3 may be engaged with one or more (or zero) adjacent weft threads 5 along the longitudinal direction 4L of the warp threads 4, or a weft thread 5 may be one side weft thread 5a for one pile thread 3, and the other side weft thread 5b or intermediate weft thread 5m for another pile thread 3 (or may be used for both purposes).

In addition, the number of weft threads 5a, 5b, 5m can be said to be one each of one side weft thread 5a and the other side weft thread 5b for one pile thread 3 described later, but the number of intermediate weft threads 5m may be one or more (one, two, three, etc.).
Therefore, the number of adjacent weft threads 5 in the weaving direction (one side weft thread 5a, the other side weft thread 5b, and the intermediate weft thread 5m) with which each pile thread 3 is engaged can be said to be two or more. In particular, if there are two adjacent weft threads 5 in the weaving direction with which each pile thread 3 is engaged, there will be one one side weft thread 5a and one other side weft thread 5b, and no intermediate weft thread 5m. If there are three or more weft threads 5 before and after the weaving direction with which each pile thread 3 is engaged, there will be one one side weft thread 5a and one other side weft thread 5b, and one or more intermediate weft threads 5m.

<Pile yarn 3>
As shown in FIGS. 1 to 5, a plurality of pile yarns 3 are woven into the base fabric 2 described above.
The pile yarns 3 may be in any configuration as long as they are woven into the base fabric 2. For example, the pile yarns 3 may be sandwiched between two warp yarns 4 and arranged in a plurality of positions along the weaving direction.

The pile yarn 3 may be either a filament yarn (long fiber yarn) or a spun yarn (short fiber yarn, spun yarn). If it is a filament yarn, it may be a monofilament or multifilament, or it may be an unprocessed filament yarn (raw silk).
The fineness (total fineness) of the pile yarn 3 is not particularly limited, but may be, for example, 20d (denier) or more and 1500d or less, preferably 50d or more and 1000d or less, and more preferably 100d or more and 600d or less. The single fiber fineness of the pile yarn 3 is also not particularly limited, but may be, for example, 0.1d (denier) or more and 1500d or less, preferably 0.5d or more and 1000d or less, and more preferably 1d or more and 600d or less.

The material of the pile yarn 3 is also not particularly limited, and may be, for example, polyester fiber such as PET, cotton fiber, rayon fiber, nylon fiber, acetate fiber, or twisted or blended yarns thereof.
The number of pile yarns 3 per inch is not particularly limited, and may be, for example, 10 or more and 100 or less.

As described above, each pile yarn 3 may be secured to one of the weft yarns 5 by passing under that weft yarn 5 .
In this case, it can be said that each pile yarn 3 constitutes a loose pile. Also, in this case, it can be said that each pile yarn 3 is not anchored to the warp yarns 4.

Furthermore, as described above, each pile yarn 3 may be engaged with three or more adjacent weft threads 5 (the above-mentioned one side weft thread 5a, the other side weft thread 5b, and the intermediate weft thread 5m) in the weaving direction by passing under one or more weft threads 5 of the three or more adjacent weft threads 5, after passing over another one or more weft threads 5 of the three or more adjacent weft threads 5 and then passing under yet another one or more weft threads 5 of the three or more adjacent weft threads 5.
In this case, each pile yarn 3 can be said to constitute a fast pile. Also in this case, each pile yarn 3 can be said to be not anchored to the warp yarns 4.

In the case where each pile thread 3 is engaged with three or more weft threads 5, each pile thread 3 is engaged in the following manner: <1-1-1> Every time it passes under one weft thread 5 of the three or more adjacent weft threads 5, it passes over another weft thread 5 of the three or more adjacent weft threads 5, and then passes under yet another weft thread 5 of the three or more adjacent weft threads 5 to be engaged therewith; or <1-1-2> Every time it passes under one weft thread 5 of the three or more adjacent weft threads 5, it passes over another weft thread 5 of the three or more adjacent weft threads 5, and then passes over another weft thread 5 of the three or more adjacent weft threads 5 to be engaged therewith; <1-2-1> every time the weft thread 5 of the three or more adjacent weft threads 5 passes under one weft thread 5 of the three or more adjacent weft threads 5, it passes over another weft thread 5 of the three or more adjacent weft threads 5 and is then engaged thereunder; or <1-2-2> every time the weft thread 5 of the three or more adjacent weft threads 5 passes under one weft thread 5 of the three or more adjacent weft threads 5, it passes over another weft thread 5 of the three or more adjacent weft threads 5 and is then engaged thereunder; <2-1-1> each time the yarn passes under a plurality of wefts 5 in the three or more adjacent wefts 5, it passes over another weft 5 in the three or more adjacent wefts 5 and then passes under yet another weft 5 in the three or more adjacent wefts 5 and then passes under yet another weft 5 in the three or more adjacent wefts 5 and then passes under yet another weft 5 in the three or more adjacent wefts 5 and then passes under yet another weft 5 in the three or more adjacent wefts 5 and then passes under yet another weft 5 in the three or more adjacent wefts 5 and then or <2-2-1> each time it passes under a number of wefts 5 in the three or more adjacent wefts 5, it passes over another number of wefts 5 in the three or more adjacent wefts 5, and then passes under yet another weft 5 in the three or more adjacent wefts 5 to be retained; or <2-2-2> each time it passes under a number of wefts 5 in the three or more adjacent wefts 5, it passes over another number of wefts 5 in the three or more adjacent wefts 5, and then passes under yet another number of wefts 5 in the three or more adjacent wefts 5 to be retained.

<One side pile piece portion 3A, the other side pile piece portion 3B, etc.>
1 to 4, the one side pile piece 3A and the other side pile piece 3B are portions of each pile yarn 3 that protrude from the above-mentioned base fabric 2. The protruding surfaces of these pile pieces 3A, 3B are also referred to as the pile surfaces of the pile fabric 1.
Each pile yarn 3 has an intermediate portion 3M between the above-mentioned one side pile piece portion 3A and the other side pile piece portion 3B, and this intermediate portion 3M can also be said to be the portion of each pile yarn 3 that does not protrude from the above-mentioned base fabric 2.

When each pile yarn 3 is engaged with one weft yarn 5, the above-mentioned one-side pile piece portion 3A passes under one weft yarn 5 and then protrudes from the base fabric 2 on one side of the one weft yarn 5.
In this case, the above-mentioned other side pile piece portion 3B passes under one weft yarn 5 and then protrudes from the base fabric 2 on the other side of the one weft yarn 5.

On the other hand, when each pile yarn 3 is engaged with three or more adjacent weft yarns 5, the above-mentioned one-side pile piece portion 3A passes under the one-side weft yarn (one-side weft yarn) 5a of the three or more adjacent weft yarns 5 and then protrudes from the base fabric 2 on one side of the one-side weft yarn 5a.
In this case, the above-mentioned other side pile piece 3B passes under the other-most weft thread (other side weft thread) 5b among three or more adjacent weft threads 5, and then protrudes from the base fabric 2 on the other side of the other-most weft thread 5b.

The angle of the one side pile piece portion 3A and the other side pile piece portion 3B of each pile yarn 3 with respect to the base fabric 2 (the upper surface (front surface) of the base fabric 2) may be approximately 90°.
In addition, the pile piece portion 3A on one side and the pile piece portion 3B on the other side of each pile yarn 3 may be inclined with respect to the base fabric 2, and in this case the angle (inclination angle) may be 10° or more and 80° or less, preferably 30° or more and 75° or less, and more preferably 50° or more and 70° or less (60° or 65°, etc.).

In order to incline the one side pile piece portion 3A and the other side pile piece portion 3B of each pile yarn 3 with respect to the base fabric 2, a tension difference (tension difference) may be applied to a set of adjacent warp yarns 4 (e.g. a set of two) among the warp yarns 4 that make up the base fabric 2 during weaving. Alternatively, the one side pile piece portion 3A and the other side pile piece portion 3B may be inclined with respect to the base fabric 2 by arranging a plurality of pile yarns 3 along the weaving direction between a set of thick warp yarns that make up the base fabric 2 and a warp yarn that is thinner than the thick warp yarn.
The vertical length (pile length) of each pile yarn 3 means the vertical length of each pile piece 3A, 3B, and is not particularly limited, but may be, for example, 0.1 mm or more and 10.0 mm or less, preferably 0.5 mm or more and 8.0 mm or less, and more preferably 1.0 mm or more and 6.0 mm or less (e.g., 3.0 mm).

From here on, the relationship between the total number of weft threads 5 and the number of intermediate weft threads 5m, and the intermediate portion 3M of each pile thread 3 when each pile thread 3 is engaged with three or more weft threads 5 will be described below.
When the total number of weft threads 5 is three, there is one each of one side weft thread 5a and the other side weft thread 5b, and therefore there is one intermediate weft thread 5m. With respect to the three weft threads 5 adjacent (before and after) in the weaving direction (one each of one side weft thread 5a, the other side weft thread 5b, and the intermediate weft thread 5m), each pile thread 3 passes under the weft thread 5a on the closest side, then over one intermediate weft thread 5m, and then under the weft thread 5b on the closest side.

Furthermore, when the total number of weft threads 5 is four, there will be one each of one side weft thread 5a and the other side weft thread 5b, and therefore the number of intermediate weft threads 5m will be two, and each pile thread 3 may pass under the weft thread 5a closest to one side of the four weft threads 5 adjacent in the weaving direction (each of which is one one side weft thread 5a or one other side weft thread 5b, and two intermediate weft threads 5m), and then, for example, pass over the two intermediate weft threads 5m together, and then pass under the weft thread 5b closest to the other side.
Similarly, when the total number of weft threads 5 is five, there is one each of one side weft thread 5a and the other side weft thread 5b, so the number of intermediate weft threads 5m is three, and each pile thread 3 passes under the weft thread 5a closest to one side of the five weft threads 5 adjacent in the weaving direction (each of which is one one side weft thread 5a or one other side weft thread 5b, and three intermediate weft threads 5m), and then passes over one intermediate weft thread 5m for every intermediate weft thread 5m it passes over (of the three intermediate weft threads 5m, it passes over the intermediate weft thread 5m closest to one side, then passes under the intermediate weft thread 5m in the center in the weaving direction, and then passes over the intermediate weft thread 5m closest to the other side), and then passes under the weft thread 5b on the other side.

Furthermore, when the total number of weft threads 5 is six, there will be one each of one side weft thread 5a and the other side weft thread 5b, so the number of intermediate weft threads 5m will be four, and each pile thread 3 will pass under the weft thread 5a on the most one side of the six weft threads 5 adjacent to it in the weaving direction (each of which is one one side weft thread 5a and one other side weft thread 5b, and four intermediate weft threads 5m), and then, for example, pass over two intermediate weft threads 5m every time it passes over two intermediate weft threads 5m (of the four intermediate weft threads 5m, it passes over the intermediate weft thread 5m on the most one side and the intermediate weft thread 5m on one side at the center in the weaving direction together, then passes over the intermediate weft thread 5m on the other side at the center in the weaving direction and the intermediate weft thread 5m on the most other side together), and then pass under the weft thread 5b on the most other side.
The same applies to the case where the total number of weft threads 5 is seven or more.

<Method of manufacturing pile fabric 1>
The manufacturing method of the pile fabric 1 according to the embodiment of the present invention is a manufacturing method of the pile fabric 1 in which the pile yarns 3 are woven into the base fabric 2 described above (hereinafter, also referred to as "the manufacturing method").
In this manufacturing method, a base fabric 2 is woven with warp yarns 4 and weft yarns 5, and pile yarns 3 are engaged with the weft yarns 5 of the base fabric 2. The weft yarns 5 are filament yarns, and the filament weft yarns 5 are false-twisted and/or heat-treated to form crimps and/or undulations.

Here, the process of weaving the base fabric 2 with the warp threads 4 and the weft threads 5 and locking the pile threads 3 to the weft threads 5 of the base fabric 2 may be referred to as the weaving process. In this weaving process, two pile fabrics (two base fabrics) woven in a double layer above and below are connected to the pile threads 3 that lock to the weft threads 5 of the two base fabrics, or the pile fabric (one base fabric) may be woven in a single layer by locking the pile threads 3 to the weft threads 5 of the one base fabric.
In addition, the process of forming crimps and/or undulations in the weft yarn 5, which is a filament yarn, by false twisting and/or heat treatment may be referred to as a yarn treatment process. In other words, the manufacturing method includes a weaving process and a yarn treatment process.

In this manufacturing method, it can be said that first, crimps and/or ripples are formed in the weft yarn 5, which is a filament yarn, in a yarn processing step, and after the yarn processing step, the base fabric 2 is woven together with the warp yarn 4 using the weft yarn 5, which is a filament yarn in which crimps and/or ripples have been formed in the yarn processing step, and the pile yarn 3 is engaged with the weft yarn 5, which is a filament yarn in which crimps and/or ripples have been formed.
In addition to the yarn processing step and the weaving step, the manufacturing method may include a center-cut step in which, as described above, two pile fabrics are woven into upper and lower double pile fabrics, and the pile yarn 3 connecting the two pile fabrics is center-cut along a line approximately in the center of the upper and lower pile fabrics 1 to divide the fabric into two pile fabrics 1. When the center-cut step is included, the order of steps in the manufacturing method is the yarn processing step, the weaving step, and the center-cut step.

＜Other＞
The present invention is not limited to the above-described embodiment. The individual components of the pile fabric 1, the manufacturing method of the pile fabric 1, and the like, or the overall structure, shape, dimensions, etc., can be appropriately changed in accordance with the spirit of the present invention.
Each pile yarn 3 is engaged with a plurality of adjacent weft threads 5 by passing under the plurality of weft threads 5 collectively, and may have a one-side pile piece portion 3A which passes under the weft thread 5a on the most one side of the plurality of weft threads 5 and then protrudes from the base fabric 2 on one side of the one-side weft thread 5a, and an other-side pile piece portion 3B which passes under the weft thread 5b on the most other side of the plurality of weft threads 5 and then protrudes from the base fabric 2 on the other side of the other-side weft thread 5b.
In this case, each pile yarn 3 can also be said to form a loose pile in a certain sense. Also, in this case, each pile yarn 3 can also be said to be not anchored to the warp yarns 4.

In the case where each pile yarn 3 is engaged with a plurality of adjacent weft yarns 5, "after passing under one or more weft yarns 5 of the adjacent plurality of weft yarns 5, and then passing over another one or more weft yarns 5 of the adjacent plurality of weft yarns 5" means that, after passing under a first certain one or more weft yarns 5 of the adjacent plurality of weft yarns 5, the pile yarn 3 passes over the first other one or more weft yarns 5, passes under a second certain one or more weft yarns 5, and then passes over the second certain one or more weft yarns 5. When a weft thread 5 passes over one or more weft threads 5 that are the first, second, third, ..., nth, and then over one or more weft threads 5, and then under one or more weft threads 5 that are the third,..., and then under one or more weft threads 5 that are the nth, the number of weft threads 5 that pass under or over them may all be the same, or they may all be different, or only two or three may be the same, etc.
A synthetic resin such as an acrylic resin adhesive may be applied to the back surface of the base fabric 2 to form a back coating (backing). Note that the back surface of the base fabric 2 in FIG. 3 is not back coated.
As described above, the manufacturing method of the pile fabric 1 may include a backing step of applying a synthetic resin such as an acrylic resin adhesive to the back surface of the base fabric 2 to perform back coating (backing). When the backing step and the center-cut step are included, the order of the steps in the manufacturing method may be yarn processing step, weaving step, center-cut step, and backing step, or may be yarn processing step, weaving step, backing step, and center-cut step.
The manufacturing method of the pile fabric 1 may include a shearing step of shearing the single woven loop pile instead of the center cutting step.

The pile fabric according to the present invention and the pile fabric produced by the pile fabric production method can be used as a cosmetic puff (cosmetic puff), a rubbing material for liquid crystal panels, a puff material for polishing paint on automobile bodies, a gap brush for sashes, a brush for home appliances, a mop material, a rotating brush (a brush in which the pile yarn side of the pile fabric is rotated while being applied to the object to be cleaned, etc.), an interior material such as upholstery fabric, curtains, wall covering, and cushioning material, and can be used as a material for passenger cars, railway cars, buses, etc. It can be used as the covering material for chairs (seats) in aircraft, etc., and for apparel products (clothing). It can also be used around the suction port of a vacuum cleaner nozzle, and can be used to wipe away dust from the surface of fabrics, clothes, sheets, sofas and beds, seats, LCD panels, plastic films, and metal sheets, and can be used in any product that sweeps up dust.

Reference Signs List 1 Pile fabric 2 Base fabric 3 Pile yarn 3A One side pile piece 3B Other side pile piece 4 Warp yarn 5 Weft yarn 5a One side weft yarn 5b Other side weft yarn

Claims (6)

A pile fabric in which pile yarn (3) is woven into a base fabric (2),
The base fabric (2) is woven with warp yarns (4) and weft yarns (5),
The pile yarn (3) is engaged with the weft yarn (5) of the base fabric (2),
The weft yarn (5) is a multifilament yarn having crimp and/or ripple formed therein ,
The pile fabric for puffs is characterized in that the single fiber fineness of the weft yarn (5) is 1.67d or more and 2.5d or less . A pile fabric in which pile yarn (3) is woven into a base fabric (2),
The base fabric (2) is woven with warp yarns (4) and weft yarns (5),
The pile yarn (3) is engaged with the weft yarn (5) of the base fabric (2),
The warp yarn (4) is a filament yarn that is not crimped and/or wavy,
The weft yarn (5) is a multifilament yarn having crimp and/or ripple formed therein ,
The pile fabric is characterized in that the single fiber fineness of the weft yarn (5) is 1.67d or more and 2.5d or less . A pile fabric in which pile yarn (3) is woven into a base fabric (2),
The base fabric (2) is woven with warp yarns (4) and weft yarns (5),
The pile yarn (3) is engaged with the weft yarn (5) of the base fabric (2),
The warp yarn (4) is a filament yarn that is not crimped and/or wavy,
The pile fabric is characterized in that the weft yarn (5) is a spun yarn. A pile fabric having dimensional stability, in which pile yarn (3) is woven into a base fabric (2),
The base fabric (2) is woven with warp yarns (4) and weft yarns (5),
The pile yarn (3) is engaged with the weft yarn (5) of the base fabric (2),
The shrinkage of the weft yarn (5) is greater than the shrinkage of the warp yarn (4),
The shrinkage ratio of the weft yarn (5) is calculated by calculating a certain length (L15) in the weft direction of the pile fabric approximately along the longitudinal direction (5L) of the weft yarn (5) in the pile fabric, a length (L25) of the weft yarn (5) itself which is woven into the pile fabric and corresponds to the certain length (L15) in the weft direction of the pile fabric, and a difference (ΔL5) between the length (L25) of the weft yarn (5) itself and the certain length (L15) in the weft direction of the pile fabric, and the ratio (S5) of the difference (ΔL5) to the certain length (L15) in the weft direction of the pile fabric,
The shrinkage ratio of the warp threads (4) is a ratio (S4) of the pile fabric to the fixed length (L14) in the warp direction of the pile fabric, the fixed length (L14) of the pile fabric being approximately along the longitudinal direction (4L) of the warp threads (4), the length (L24) of the warp threads (4) themselves which are woven into the pile fabric and correspond to the fixed length (L14) in the warp direction of the pile fabric, and the difference (ΔL4) between the length (L24) of the warp threads (4) themselves and the fixed length (L14) in the warp direction of the pile fabric, Each pile yarn (3) is secured to one weft yarn (5) by passing under the weft yarn (5);
5. The pile fabric according to claim 1, wherein each of the pile yarns (3) has a one-side pile piece portion (3A) which passes under the single weft yarn (5) and then protrudes from the base fabric (2) on one side of the single weft yarn (5), and an other-side pile piece portion (3B) which passes under the single weft yarn (5) and then protrudes from the base fabric (2) on the other side of the single weft yarn ( 5 ). A method for manufacturing a pile fabric in which pile yarn (3) is woven into a base fabric (2),
The base fabric (2) is woven with warp yarns (4) and weft yarns (5),
The pile yarn (3) is engaged with the weft yarn (5) of the base fabric (2),
The warp yarn (4) is a filament yarn that is not crimped and/or wavy,
The weft yarn (5) is a multifilament yarn,
The weft yarn (5) which is a multifilament yarn is false-twisted and/or heat-treated to form crimps and/or undulations ,
The method for producing a pile fabric is characterized in that the single fiber fineness of the weft yarn (5) is 1.67d or more and 2.5d or less .

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