JP7575758B2 - Rectangular pile fabric, support member, and manufacturing method thereof - Google Patents

Description

The present invention relates to a base fabric having warp and weft threads, a pile fabric in which pile threads are erected from the base fabric, a support member, and a method for manufacturing the same.

A loop pile holder is known which comprises a base body and a loop pile, the loop pile being disposed on the base body with its base portion bonded to the base body (Patent Document 1).
In this loop pile holder, the loop pile forming yarn forming the loop pile is approximately cylindrical in shape, and non-water-absorbent filaments of 0.05 to 0.8 denier are closely packed in the axial direction and radially outward from the axis of the loop pile forming yarn, the approximately cylindrical outer periphery being formed by the tips of the filaments, and the loop pile has a ratio of (loop pile height)/(loop pile diameter) of 1/1 to 5/1 and a ratio of (distance between the centres of both loop pile bases)/(loop pile diameter) of 3/1 or less, and is self-supporting with respect to the surface of the base.

JP 2010-18892 A

However, as shown in FIG. 1 and other figures of the loop pile holder described in Patent Document 1, the shape (appearance) of the loop pile when viewed from the side can be said to be approximately circular, and a new appearance is required.

In view of these points, the present invention aims to provide a pile fabric, a support member, and a manufacturing method thereof that can realize a "new pile appearance" by making the pile yarns approximately rectangular, etc.

A pile fabric 1 according to the present invention is a pile fabric having pile threads 3 standing up from a base fabric 2, the base fabric 2 having warp threads 4 and weft threads 5, the pile threads 3 being engaged with one or more weft threads 5, the tip end of the pile threads 3 being approximately U-shaped in side view and the base end side being approximately upright with respect to the base fabric 2 in side view, the pile threads 3 being provided at predetermined intervals in the weft direction which is the longitudinal direction of the weft threads 5, the pile fabric being used as a support member, the support member having the pile fabric and an approximately plate-shaped elastic material, and serving as a support member for supporting a solidifiable structure, the pile fabric being fixed to the outer surface of the elastic material so that the base fabric 2 is deformable in response to elastic deformation of the elastic material, and the pile threads 3 of the pile fabric being embedded in the solidifiable structure .

A second feature of the pile fabric 1 according to the present invention is that the pile fabric has pile threads 3 standing up from a base fabric 2, the base fabric 2 has warp threads 4 and weft threads 5, the pile threads 3 are engaged with one or more weft threads 5, the tip end side of the pile threads 3 is approximately U-shaped in side view, and the base end side is approximately upright with respect to the base fabric 2 in side view, the pile threads 3 are monofilament yarns and have a single fiber fineness, which is a total fineness, of 20 d or more and 3000 d or less, the warp threads 4 are multifilament yarns and have a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less, and the weft threads 5 are multifilament yarns and have a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less.
Alternatively, the pile yarns 3 may have a tip end that is substantially semicircular in side view, and a base end that is substantially upright with respect to the base fabric 2 in side view.

A third feature of the pile fabric 1 according to the present invention is that the pile fabric 1 has pile threads 3 standing up from a base fabric 2, the base fabric 2 has warp threads 4 and weft threads 5, the pile threads 3 are engaged with one or more weft threads 5, the tip end of the pile threads 3 is approximately U-shaped in side view and the base end is approximately upright with respect to the base fabric 2 in side view, the pile threads 3 are monofilament threads, and the number of the pile threads 3 per inch is 10 to 100, the warp threads 4 are multifilament threads, and the number of the warp threads 4 per inch is 10 to 30, and the weft threads 5 are multifilament threads, and the number of the weft threads 5 per inch is 20 to 250.
Alternatively, the pile yarns 3 may be monofilament yarns, and the warp yarns 4 may be disposed between adjacent pile yarns 3 in the weft direction, which is the longitudinal direction of the weft yarns 5 .

Alternatively, the pile yarn 3 may be engaged with three or more adjacent weft threads 5 in the warp direction, which is the longitudinal direction of the warp threads 4, and each time the pile yarn 3 passes under one or more weft threads 5 of the three or more adjacent weft threads 5, the pile yarn 3 may pass over another one or more weft threads 5 of the three or more adjacent weft threads 5, and then pass under yet another one or more weft threads 5 of the three or more adjacent weft threads 5 to be engaged therewith.

Due to these characteristics, the tip end of the pile yarn 3 which is engaged with one or more weft yarns 5 is made roughly U-shaped in side view, and the base end is made roughly upright with respect to the base fabric 2 in side view, so that the pile yarn 3 has a roughly rectangular shape, etc., which differs from Patent Document 1 in that the appearance of the loop pile in side view is roughly circular, thereby achieving a "new pile appearance."
Incidentally, such a pile fabric 1 can also be said to be a "pile fabric having a substantially rectangular shape, etc."
Alternatively, the tip end of the pile yarn 3 may be substantially semicircular in side view, and the base end may be substantially upright with respect to the base fabric 2 in side view.

In addition, by using monofilament pile yarns 3 and arranging multiple warp yarns 4 between adjacent pile yarns 3 in the weft direction, pile yarns 3 of approximately rectangular shape, etc. can be erected at a predetermined interval in the weft direction, realizing a pile with a more modern appearance.

Furthermore, by engaging the pile yarn 3 with three or more weft yarns 5 adjacent in the warp direction, the width of the pile yarn 3 in the warp direction, which is generally rectangular or the like, is ensured to be equal to or greater than a predetermined value, resulting in a pile with a more innovative appearance, while at the same time making the pile yarn 3 in the generally rectangular or the like shape less likely to come loose (achieving both a "new appearance for the pile" and "improved pile pull-out prevention").

The support member of the present invention has the above-mentioned pile fabric 1 and a substantially plate-shaped elastic material, and is a support member for supporting a solidifiable structure, and has a first feature in that the pile fabric 1 is fixed to the outer surface of the elastic material so that the base fabric 2 is deformable in response to the elastic deformation of the elastic material, and the pile yarns 3 of the pile fabric 1 are embedded in the solidifiable structure.
A second feature of the support member according to the present invention is a pile fabric 1 having pile threads 3 standing up from a base fabric 2, the base fabric 2 having warp threads 4 and weft threads 5, the pile threads 3 being engaged with one or more weft threads 5, the tip end of the pile threads 3 being approximately U-shaped in side view and the base end side being approximately upright with respect to the base fabric 2 in side view, the pile threads 3 being arranged at predetermined intervals in the weft direction which is the longitudinal direction of the weft threads 5, and the pile fabric 1 having an approximately plate-shaped elastic material, the support member for supporting a solidifiable structure, the pile fabric 1 being fixed to the outer surface of the elastic material so that the base fabric 2 is deformable in response to elastic deformation of the elastic material, and the pile threads 3 of the pile fabric 1 being embedded in the solidifiable structure.

Due to this feature, the pile fabric 1 is fixed to the outer surface of the elastic material so that the base fabric 2 can deform in response to the elastic deformation of the elastic material, and the pile yarns 3 of the pile fabric 1 are embedded in the hardenable structure, so that the support member supports a hardenable structure such as a roughly rod-shaped concrete structure, while preventing the support member from misaligning with the hardenable structure, stabilizing the support ("stabilized support").

The method for manufacturing a pile fabric 1 according to the present invention is a method for manufacturing a pile fabric having pile threads 3 standing up from a base fabric 2, and includes a weaving step S1 in which a front base fabric 2a and a back base fabric 2b each having a warp thread 4 and a weft thread 5 are connected with a connecting thread 3' engaged with two or more of the weft threads 5 to weave the base fabric 2 and the pile threads 3, a heat treatment step S2 in which the front base fabric 2a and/or the back base fabric 2b are heat-treated after the weaving step S1, and a dissolving step S3 in which the weft threads 5 contain soluble fibers and the soluble fibers are dissolved, and the tip side of the connecting threads 3' is approximately U-shaped in side view, a pile fabric (5) that is fixed to an outer surface of the elastic material so that the base fabric (2) is deformable in response to elastic deformation of the elastic material, and the pile fabric (5) is embedded in the solidifiable structure.
A second feature of the method for manufacturing the pile fabric 1 according to the present invention is a method for manufacturing a pile fabric having pile threads 3 standing up from a base fabric 2, the method including a weaving step S1 for connecting a front base fabric 2a and a back base fabric 2b each having a warp thread 4 and a weft thread 5 with a connecting thread 3' engaged with two or more weft threads 5 to weave the base fabric 2 and the pile threads 3, a heat treatment step S2 for heat-treating the front base fabric 2a and/or the back base fabric 2b after the weaving step S1, and a dissolving step S3 for dissolving the soluble fiber, in which the weft threads 5 contain soluble fibers, and the connecting threads 3' are connected to the front base fabric 2a and the back base fabric 2b. the pile yarn 3 has a tip end side which is substantially U-shaped in a side view and a base end side which is substantially upright with respect to the base fabric 2 in a side view, the pile yarn 3 is a monofilament yarn and has a single fiber fineness, which is a total fineness, of 20 d or more and 3000 d or less, the warp yarn 4 is a multifilament yarn and has a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less, and the weft yarn 5 is a multifilament yarn and has a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less.

The third feature of the method for manufacturing the pile fabric 1 according to the present invention is a method for manufacturing a pile fabric having pile threads 3 standing up from a base fabric 2, comprising the steps of: connecting a front base fabric 2a and a back base fabric 2b each having a warp thread 4 and a weft thread 5 with a connecting thread 3' engaged with two or more of the weft threads 5 to weave the base fabric 2 and the pile threads 3; and heat-treating the woven front base fabric 2a and/or the woven back base fabric 2b; and dissolving the soluble fiber in the weft thread 5, which contains a soluble fiber, in a dissolving step S3 . The pile yarns 3 are formed so that their end sides are substantially U-shaped in side view and their base end sides are substantially upright with respect to the base fabric 2 in side view , the pile yarns 3 are monofilament yarns and have a single fiber fineness, which is a total fineness, of 20 d or more and 3000 d or less, the warp yarns 4 are multifilament yarns and have a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less, and the weft yarns 5 are multifilament yarns and have a total fineness of 20 d or more and 1500 d or less and a single fiber fineness of 1 d or more and 600 d or less .

In addition, the weft yarn 5 may contain soluble fibers, and a dissolving step S3 may be provided for dissolving the soluble fibers.

Due to these features, after the weaving step S1, a heat treatment step S2 is provided in which the front base fabric 2a and the back base fabric 2b are heat-treated, and the connecting yarns 3' between the front base fabric 2a and the back base fabric 2b are formed into pile yarns 3 whose tip end is approximately U-shaped in side view and whose base end is approximately upright relative to the base fabrics 2 in side view. This makes the pile yarns 3 approximately rectangular or the like, which differs from Patent Document 1 in that the appearance of the loop pile in side view is approximately circular. At the same time, a "new pile appearance" can be realized. At the same time, two pile fabrics 1 having pile yarns 3 each having an approximately rectangular shape or the like can be produced by performing the weaving step S1 and the heat treatment step S2 only once, thereby improving the production efficiency of the pile fabric 1 (the "new pile appearance" and the "improved production efficiency" can be achieved at the same time).
Incidentally, the manufacturing method of such pile fabric 1 can also be said to be a "manufacturing method of pile fabric having a substantially rectangular shape, etc."
In addition, a weaving/heat treatment step S1' may be provided in which the weaving step S1 and the heat treatment step S2 are combined into one step.

In addition, by providing a dissolving step S3 for dissolving the soluble fibers contained in the weft yarn 5, the weft yarn 5 containing the soluble fibers to which the connecting yarn 3' is attached dissolves and is released from the attachment, and the front base fabric 2a and the back base fabric 2b can be quickly separated without cutting the connecting yarn 3' which becomes the pile yarn 3 having a substantially rectangular shape, etc., thereby achieving both a further "new appearance of the pile" and "improved manufacturing efficiency."

The manufacturing method of the support member according to the present invention is a manufacturing method of a support member that has pile fabric 1 manufactured by the manufacturing method described above and a substantially plate-shaped elastic material and supports a solidifiable structure, and is characterized in that it includes a fixing step of fixing the pile fabric 1 to the outer surface of the elastic material so that the base fabric 2 is deformable in response to the elastic deformation of the elastic material, and an embedding step of embedding the pile yarns 3 of the pile fabric 1 in the solidifiable structure.

Due to this feature, by providing a fixing process for fixing the pile fabric 1 to the outer surface of the elastic material so that the base fabric 2 can deform in response to the elastic deformation of the elastic material, and an embedding process for embedding the pile yarns 3 of the pile fabric 1 in a hardenable structure, the support member supports a hardenable structure such as a roughly rod-shaped concrete structure, while preventing the support member from misaligning with the hardenable structure, stabilizing the support ("stabilized support").

The pile fabric, support member, and manufacturing method thereof according to the present invention can achieve a "new pile appearance" by forming the pile yarn into a roughly rectangular shape, etc.

1 is a photograph substituting a drawing illustrating a perspective view of the surface of a pile fabric or the like according to the present invention. 1 is a photograph showing an example of a longitudinal view of warp yarns of a pile fabric or the like; 1 is a drawing substitute photograph illustrating an oblique view of the process of separating a front base fabric and a back base fabric in a manufacturing method of pile fabrics and the like according to the present invention, in which both the front base fabric and the back base fabric are pile fabrics. This is a drawing substitute photograph illustrating the longitudinal view of the warp threads of a pile fabric in the process of separating the front base fabric and the back base fabric when both the front base fabric and the back base fabric are pile fabrics in a manufacturing method of pile fabric, etc. 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. In the case where both the front and back base fabrics are pile fabrics in the pile fabric manufacturing method, this is a structure diagram of the back base fabric in the pile fabric (with one intermediate weft) before the front and back base fabrics are separated. Note that the black in Fig. 6 means that the warp yarn or pile yarn passes above (or above) the weft yarn in a plan view (plan view from the front base fabric side). Also, the symbol attached to the weft yarn in Fig. 6 indicates the symbol of the weft yarn in the cross-sectional view taken along the X-X arrow. As in Fig. 6, this is a diagram of the structure of the front base fabric in a pile fabric before the front base fabric and the back base fabric are separated. Note that the black in Fig. 7 also means that the warp yarns or pile yarns pass above (or above) the weft yarns in a plan view (plan view from the back of the front base fabric). The reference numerals attached to the weft yarns in Fig. 7 also indicate the reference numerals of the weft yarns in the cross-sectional view taken along the X-X arrow. 8A and 8B are cross-sectional views taken along the line X-X in the pile fabric illustrated in the structure diagrams of FIGS. 6 and 7, in which (a) shows the pile fabric before the front and back base fabrics are separated, and (b) shows the pile fabric after the front and back base fabrics have been separated after the dissolving step. 8A and 8B are cross-sectional views taken along the line Y-Y in the pile fabric illustrated in the structure diagrams of FIGS. 6 and 7, in which (a) shows the pile fabric before the front base fabric and the back base fabric are separated, and (b) shows the pile fabric after the front base fabric and the back base fabric are separated after the dissolving step. 8A and 8B are cross-sectional views taken along the line Z-Z in the pile fabric illustrated in the structure diagrams of FIGS. 6 and 7, in which (a) shows the pile fabric before the front base fabric and the back base fabric are separated, and (b) shows the pile fabric after the front base fabric and the back base fabric are separated after the dissolving step. 8 is a cross-sectional view taken along the line V-V of the pile fabric illustrated in the structure diagrams of FIGS. 6 and 7, in which (a) shows the pile fabric before the front base fabric and the back base fabric are separated, and (b) shows the pile fabric after the front base fabric and the back base fabric are separated after the dissolving step. 8A and 8B are cross-sectional views taken along the line W-W of the pile fabric illustrated in the structure diagrams of FIGS. 6 and 7, in which (a) shows the pile fabric before the front and back base fabrics are separated, and (b) shows the pile fabric after the front and back base fabrics have been separated after the dissolving step. FIG. 1 is a flowchart showing a method for manufacturing pile fabrics and the like according to the present invention, in which (a) shows a first embodiment, (b) shows a second embodiment, (c) shows a third embodiment, and (d) illustrates a modified example.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
<Overall configuration of pile fabric 1>
1 to 12 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 threads 3 woven into the base fabric 2, and it can also be said that the pile threads 3 stand upright from 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 (a 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 15.0 mm or less, preferably 0.7 mm or more and 10.0 mm or less, and more preferably 1.0 mm or more and 5.0 mm or less.

<Base fabric 2>
As shown in Figures 1 to 12, the base fabric 2 has warp threads 4 described later and weft threads 5 described later (one end side weft threads 5a, the other end side weft threads 5b, and intermediate weft threads 5m), and is formed by weaving these warp threads 4 and weft threads 5.
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 12, 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 warp threads 4 may be arranged between adjacent pile threads 3 in the weft direction (the weft direction which is the longitudinal direction of the weft threads 5), and between adjacent pile threads 3, the warp threads 4 may be arranged in the form of multiple threads aligned together.

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>
As shown in Figures 1 to 12, 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) in 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 composition 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 threads 4 are filament threads, the warp threads 4 may have crimps or undulations formed therein, or the warp threads 4 may not have crimps or undulations formed therein (the warp threads 4 may be filament threads (raw silk) that have not been processed in any way).
The weft yarn 5 may also be a spun yarn (staple fiber yarn, spun yarn).
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, or twisted 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.

The pile yarns 3, which will be described later, are held against such weft yarns 5. The number of weft yarns 5 to which the pile yarns 3 are held is not particularly limited, but for example, each pile yarn 3 may be held against one or more weft yarns 5, or against three or more adjacent weft yarns 5.
Various types of weft yarns 5 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 12 (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 12, 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).
Hereinafter, the pile yarn 3 will be described as being a monofilament yarn.
The fineness (total fineness) of the pile yarn 3 is not particularly limited, but may be, for example, 20 d (denier) or more and 3000 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. The single fiber fineness of the pile yarn 3 is also 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 pile yarn 3 is similarly 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. In addition, it may be a yarn obtained by doubling or aligning a non-thermoplastic fiber such as cotton fiber or rayon fiber with a thermoplastic fiber such as polyester fiber, nylon fiber, or acetate fiber.
The number of pile yarns 3 per inch is not particularly limited, and may be, for example, 10 or more and 100 or less.

Such pile yarns 3 have a tip (pile tip 3a) that is generally U-shaped in side view, and/or a base (pile base 3b) that is generally upright with respect to the base fabric 2 in side view.
The pile yarn 3 is a loop pile. Therefore, in one loop pile (one loop pile portion of the pile yarn 3), the pile base end 3b side described above has two portions (standing portions 3A, 3B) extending in the standing direction of the pile yarn 3, and the angle (standing angle) α of each of the two standing portions 3A, 3B with the base fabric 2 in a side view (standing angle) may be approximately 90°, or the standing angle α may be 70° or more and 90° or less, preferably 80° or more and 90° or less, and more preferably 85° or more and 90° or less. The standing angles α of the two standing portions 3A, 3B may be approximately the same or different from each other, and in addition, there may be a rounded portion (approximately a quarter circle portion in a side view) between each of the two standing portions 3A, 3B and the base fabric 2.

On the other hand, the pile tip 3a side of one loop pile portion has two portions (standing portions 3A, 3B) extending in the standing direction (up-down direction) of the pile yarn 3, and one portion (connecting portion 3C) extending from each of the tip sides of the standing portions 3A, 3B approximately parallel to the surface of the base fabric 2 (warp direction, front-to-rear direction) to connect the front and rear standing portions 3A, 3B, and the angle (connecting angle) β between each of the two standing portions 3A, 3B and the connecting portion 3C in side view (connecting angle) β may be approximately 90°, or the connecting angle β may be 60° or more and 90° or less, preferably 70° or more and 90° or less, and more preferably 80° or more and 90° or less. In addition, the connection angle β between each of the two standing portions 3A, 3B and the connecting portion 3C may be approximately the same or different, and further, there may be a rounded portion (approximately a quarter-circle portion in side view) between each of the two standing portions 3A, 3B and the connecting portion 3C.
Alternatively, the pile yarn 3 may have a substantially semicircular shape on the pile tip 3a side in side view, and at the same time, the pile base end 3b side may be substantially upright relative to the base fabric 2 in side view. In this case, the pile yarn 3 can be said to have a substantially half-circular shape in side view from the tip (top end) of the standing portion 3A on one side, through the connecting portion 3C, to the tip (top end) of the standing portion 3B on the other side.

As described above, each pile yarn 3 described above may be anchored to one or more weft yarns 5, or may be anchored to three or more weft yarns 5 adjacent to each other in the warp direction.
When each pile yarn 3 is held by one or more weft yarns 5, if the pile yarn 3 is held by only one weft yarn 5, the pile yarn 3 passes under the weft yarn 5 and is held by the one weft yarn 5. In this case, the pile yarns 3 can be said to form a loose pile. In addition, in this case, the pile yarns 3 can be said to be not held by the warp yarns 4.

When each pile yarn 3 is held by one or more weft yarns 5, if the pile yarn 3 is held by only two adjacent weft yarns (before and after) in the weaving direction, it passes continuously under the two weft yarns 5 and is held by them (if the pile yarn 3 passes under only one of the two weft yarns 5 and is held by them, it corresponds to the above-mentioned case where the pile yarn 3 is held by only one weft yarn 5). In this case, each pile yarn 3 can also be said to form a loose pile. Also, in this case, each pile yarn 3 can also be said to not be held by any warp yarn 4.
Various types of weft yarns 5 in which the pile yarn 3 is held by three or more adjacent weft yarns 5 will be described below.

Furthermore, as described above, each pile thread 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.

To explain in detail the case where each pile yarn 3 is engaged with three or more weft yarns 5, each pile yarn 3 passes under one weft yarn 5 of the three or more adjacent weft yarns 5, passes over another weft yarn 5 of the three or more adjacent weft yarns 5, and is then engaged with the other weft yarn 5 of the three or more adjacent weft yarns 5; or, <1-1-2> each time the pile yarn 3 passes under one weft yarn 5 of the three or more adjacent weft yarns 5, passes over another weft yarn 5 of the three or more adjacent weft yarns 5, and is then engaged with the three or more adjacent weft yarns 5. <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, the weft thread 5 passes over another weft thread 5 of the three or more adjacent weft threads 5, and then passes under another weft thread 5 of the three or more adjacent weft threads 5, and then passes under another weft thread 5 of the three or more adjacent weft threads 5, and then passes under another weft thread 5 of the three or more adjacent weft threads 5, and then passes under another weft thread 5 of the three or more adjacent weft threads 5, and then passes under another weft thread 5 of the three or more adjacent weft threads 5, and or <2-1-1> each time it 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, or <2-1-2> each time it 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 plurality of wefts 5 in the three or more adjacent wefts 5, It may be engaged in the following manner: <2-2-1> each time it passes under a plurality of weft threads 5 of the three or more adjacent weft threads 5, it passes over another plurality of weft threads 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 and then becomes engaged; or <2-2-2> each time it passes under a plurality of weft threads 5 of the three or more adjacent weft threads 5, it passes over another plurality of weft threads 5 of the three or more adjacent weft threads 5 and then becomes engaged.
Since each pile yarn 3 is a loop pile, the pile yarn 3 is cut midway, and therefore each pile yarn 3 does not have a portion (pile piece portion) protruding from the base fabric 2. It can also be said that the loop pile portion of each pile yarn 3 has a portion extending in the vertical direction (i.e., standing portion 3A on one side (front side) and standing portion 3B on the other side (rear side)) and a portion extending in the warp direction (front-rear direction) to connect the front and rear standing portions 3A, 3B (i.e., connecting portion 3C).

The vertical length (pile length) of each pile yarn 3 (loop pile portion) refers to the vertical length of each of the standing portions 3A, 3B in each of these loop pile portions, and is not particularly limited, but may be, for example, 0.1 mm or more and 30.0 mm or less, preferably 0.5 mm or more and 20.0 mm or less, and more preferably 1.0 mm or more and 10.0 mm or less (e.g., 3.5 mm, 3.41 mm, etc.).
The warp length (front-to-back length) of each pile yarn 3 (loop pile portion) refers to the warp length of the connecting portion 3C in each of these loop pile portions, and is not particularly limited, but may be, for example, 0.1 mm or more and 10.0 mm or less, preferably 0.3 mm or more and 7.0 mm or less, and more preferably 0.5 mm or more and 5.0 mm or less (e.g., 2.0 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 closest to one side, then over one intermediate weft thread 5m, and then under the weft thread 5b closest to the other 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, and therefore 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 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.

<Manufacturing method of pile fabric 1, weaving step S1, heat treatment step S2>
As shown in Figures 3, 4, 8 to 13, etc., 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").
The manufacturing method includes a weaving step S1 and a heat treatment step S2 (the manufacturing method including only the weaving step S1 and the heat treatment step S2 is referred to as a first embodiment).
In addition, the manufacturing method may include a dissolving step S3 (the manufacturing method including the dissolving step S3 in addition to the weaving step S1 and the heat treatment step S2 is defined as the second embodiment).

The weaving step S1 is a step of weaving the base fabric 2 and pile yarns 3 by connecting the front base fabric 2a and the back base fabric 2b, each having warp yarns 4 and weft yarns 5, with connecting yarns 3' engaged with two or more weft yarns 5.
The heat treatment step S2 is a step of heat treating the front base fabric 2a and/or the back base fabric 2b after the above-mentioned weaving step S1.

This manufacturing method includes the weaving process S1 and heat treatment process S2 described above, and forms the connecting yarn 3' into pile yarn 3 whose tip end is roughly U-shaped in side view and/or whose base end is roughly upright relative to the base fabric 2 in side view.

<Dissolving step S3>
The dissolving step S3 is a step in which the weft yarn 5 contains soluble fibers and the soluble fibers are dissolved.
Here, in the present invention, "the weft yarn 5 contains soluble fiber" means that, among the multiple weft yarns 5, one or more weft yarns 5 contain only soluble fiber (so-called soluble weft yarn 5'), or that, among the multiple weft yarns 5, one or more weft yarns 5 contain at least soluble fiber.
Hereinafter, the weft yarn 5 containing soluble fibers will be mainly described as a soluble weft yarn 5' having only soluble fibers.

In addition, the weft yarn 5 containing soluble fibers such as the soluble weft yarn 5' 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 (so-called a soluble monofilament yarn) or a multifilament (so-called a soluble multifilament yarn), or it may be a filament yarn with crimps or ripples, or it may be a filament yarn (raw silk) that has not been processed in any way.
In addition, the "soluble fiber" in the present invention is a fiber that can be dissolved, and may be, for example, a water-soluble fiber that can be dissolved in water (such as a water-soluble vinylon (PVA) fiber).
In this case, the temperature of the water at which the water-soluble fiber begins to dissolve is not particularly limited, but may be, for example, 60°C, 30°C, 55°C, 70°C, 80°C, 90°C, 95°C, or the like.

In addition, the "soluble fiber" in the present invention may be a synthetic fiber that melts at a predetermined temperature (melting point) by heat treatment or the like, for example, a polyester fiber such as low-melting point PET, or a polyolefin fiber such as low-melting point PE or low-melting point PP.
In this case, the temperature at which the soluble synthetic fibers begin to dissolve is not particularly limited, but may be, for example, 96°C to 100°C, or 110°C.

The fineness (total fineness) of the weft yarn 5 containing soluble fibers such as the soluble weft yarn 5' 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. The single fiber fineness of the weft yarn 5 containing soluble fibers is also 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.
Furthermore, when the weft yarn 5 contains soluble fibers such as a soluble weft yarn 5', the number of weft yarns 5 containing soluble fibers per inch is not particularly limited and may be, for example, 1 or more and 20 or less.

The weft yarn 5 containing soluble fibers such as the soluble weft yarn 5' described above may be used in at least one of the above-mentioned front base fabric 2a and back base fabric 2b as at least a part of the weft yarn 5 to which the connecting yarn 3' (pile yarn 3) is attached.
When the manufacturing method includes a dissolving step S3, the order of the steps in the manufacturing method may be after the above-mentioned heat treatment step S2, and in more detail, the order may be weaving step S1, heat treatment step S2, and dissolving step S3, or weaving step S1, dissolving step S3, and heat treatment step S2.

After such a dissolving step S3, only one of the front base fabric 2a and the back base fabric 2b may be made into the pile fabric 1, and the other may not have the pile yarn 3 and may not be made into the pile fabric 1 (i.e., may be made into a discarded base fabric) (i.e., a separation step (separation step of the pile fabric 1 and the discarded base fabric) S4).
Furthermore, after the dissolving step S3, the weft yarns 5 (such as the intermediate weft yarn 5m) adjacent to the front or rear (warp direction) of the dissolved soluble weft yarn 5' may shift toward the location where the soluble weft yarn 5' was located (see Figures 8 to 11(b) and the like), and the loop pile portion of the pile yarn 3 after separation may lose the trace of its engagement with the soluble weft yarn 5' and may become approximately rectangular or the like (see Figures 1 to 5 and the like).
Furthermore, after the dissolving step S3, the front base fabric 2a and the back base fabric 2b are separated (this is also a so-called separation step (a step of separating the pile fabric 1 on the front base fabric 2a side from the pile fabric 1 on the back base fabric 2b side)) S4, and both the front base fabric 2a and the back base fabric 2b may be used as the pile fabric 1 (see Figures 3 and 4), and an example of this case will be described below. Note that the manufacturing method of the pile fabric 1 according to the embodiment of the present invention includes a separation step S4 in addition to the weaving step S1, heat treatment step S2, and dissolving step S3, and this manufacturing method is referred to as the third embodiment.

<Weaving/heat treatment step S1'etc.>
In addition, in the first to third embodiments described above, the weaving step S1 and the heat treatment step S2 may be combined into one step, that is, a weaving and heat treatment step S1'.
In detail, in the weaving and heat treatment step S1', a front base fabric 2a and a back base fabric 2b each having a warp thread 4 and a weft thread 5 are weaved between the front base fabric 2a and the back base fabric 2b by using a connecting thread 3 which is connected to two or more of the weft threads 5. The base fabric 2 and the pile yarn 3 are woven together by connecting them with each other at ', and the woven front base fabric 2a and/or the woven back base fabric 2b are heat-treated.

Furthermore, if the weaving process S1 and the heat treatment process S2 in the first embodiment are combined into a single weaving/heat treatment process S1', this can be said to be a modified version of the first embodiment, and this modified version of the first embodiment will only include the weaving/heat treatment process S1'.
Similarly, if the weaving process S1 and the heat treatment process S2 in the second embodiment are combined into a single weaving/heat treatment process S1', this can be said to be a modified version of the second embodiment, and this modified version of the second embodiment includes a weaving/heat treatment process S1' and a dissolving process S3, and the order of the processes in the modified version of the second embodiment is weaving/heat treatment process S1', followed by dissolving process S3.
Furthermore, if the weaving process S1 and the heat treatment process S2 in the third embodiment are combined into a single weaving/heat treatment process S1', this can be said to be a modified version of the third embodiment (see Figure 13 (d)).This modified version of the third embodiment includes a weaving/heat treatment process S1', a dissolving process S3, and a separation process S4, and the order of the processes in the modified version of the third embodiment is the weaving/heat treatment process S1', the dissolving process S3, and the separation process S4.

<Example>
As shown in Figs. 6 to 12, in the case where the pile yarns 3 are anchored to three weft yarns 5 (one intermediate weft yarn 5m) and 18 weft yarns 5 form one complete design, if these 18 weft yarns 5 are provisionally numbered from 1 to 18, then, of the standing portions 3A and 3B of the pile yarns 3, the standing portion 3A on one side (front side) of the pile yarns 3 standing from the weft yarn 5 (one side weft yarn 5a) in the "foremost and approximately central portion (e.g., No. 1 and No. 10)" of the back base fabric 2b is designated as pile yarn 3-1, and so on. The pile yarn 3 in the one-side standing portion 3A standing up from one side weft yarn 5a of the "front and rear portion (e.g., no. 4 and no. 13)" of the back base fabric 2b is referred to as pile yarn 3-2, the pile yarn 3 in the one-side standing portion 3A standing up from the weft yarn 5 (one-side weft yarn 5a) of the "foremost portion and approximately central portion (e.g., no. 1 and no. 10)" of the front base fabric 2a is referred to as pile yarn 3-3, and the pile yarn 3 in the one-side standing portion 3A standing up from one side weft yarn 5a of the "front and rear portion (e.g., no. 4 and no. 13)" of the front base fabric 2a is referred to as pile yarn 3-4.
As viewed from the arrows W-W in Figures 6 and 7 (i.e., Figure 12), in the back base fabric 2b, the warp threads which sandwich the pile yarns 3-1, 3-3 from both sides (both sides in the longitudinal direction 5L of the weft yarn 5) and pass over the other side weft yarn 5b are designated as warp threads 4b-2, 4b-3, and the warp threads which sandwich the pile yarns 3-2, 3-4 from both sides and pass under the other side weft yarn 5b are designated as warp threads 4b-1, 4b-4.
Furthermore, in the view of the W-W arrows in Figures 6 and 7, in the surface base fabric 2a, the warp threads which sandwich the pile yarns 3-1, 3-3 from both sides and pass over the weft yarn 5 (a weft which is neither one side weft yarn 5a, the other side weft yarn 5b, the intermediate weft yarn 5m nor the soluble weft yarn 5') are also designated as warp threads 4b-2, 4b-3, and the warp threads which sandwich the pile yarns 3-2, 3-4 from both sides and pass under the weft yarn 5 are also designated as warp threads 4b-1, 4b-4.
12(a) and 12(b), in the W-W arrow view (side cross-sectional view showing the longitudinal direction of the warp threads 4), the pile yarns 3-1 to 3-4 are erected alternately from the front base fabric 2a and the back base fabric 2b, and after the front base fabric 2a and the back base fabric 2b are separated, the pile yarns 3-1 and 3-3 are erected from the back base fabric 2b, and the pile yarns 3-2 and 3-4 are erected from the front base fabric 2a. It can also be said that the connecting yarns 3' in the weaving process S1 constitute the erected portions 3A and 3B of each pile yarn 3.

<Support Member>
The support member according to the present invention comprises the pile fabric 1 described above and an elastic material, and is a member for supporting a solidifiable structure.
In the support member, the pile fabric 1 is fixed to the outer surface of the elastic material so that the base fabric 2 is deformable in response to (following) the elastic deformation of the elastic material.

In addition, the support member may have a protective material on the lower surface (lower side) of the elastic material described above.
The solidifiable structure supported by such a support member will first be described in detail.

<Solidifiable Structure>
The solidifiable structure is supported by the support member described above.
The solidifiable structural material may be composed of a cement-based solidifying material such as cement or concrete, or may be composed of any other solidifiable (or hardenable) material such as asphalt.

The shape of the solidifiable structure is not particularly limited, and may be, for example, a block body (such as a rod-shaped sleeper) having a longitudinal direction and a cross-sectional shape (cross-sectional shape viewed in the longitudinal direction) of a substantially trapezoid, or a plate body or tile body having a substantially rectangular or square planar shape. When the solidifiable structure is a sleeper, the sleeper structure may have a pair of left and right rail fixing parts spaced apart from each other, and rail fixing devices attached to both sides of the lower parts (base parts) of the left and right rails may be provided at the upper parts of the pair of left and right rail fixing parts. In addition, a support member that supports the sleeper structure is joined (fixed) to the bottom (lower side) of the sleeper structure. In addition, the sleeper structure may contain piano wire, steel bar (PC steel bar), etc. as a core material.
Each such solidifiable structure may be supported by a single support member, or alternatively, a single solidifiable structure may be supported by two or more support members, two or more solidifiable structures may be supported by a single support member, or two or more support members may be supported by two or more support members (for example, a solidifiable structure having a longitudinal direction may be supported by a support member having a longitudinal direction, with the support members shifted alternately along the longitudinal direction).

In the solidifiable structure described above, the pile yarns 3 of the pile fabric 1 in the support member are buried (embedded, in other words, anchored) before the solidifiable structure is solidified (for example, in the case where the solidifiable structure is a concrete sleeper, while the concrete sleeper is in the state of ready-mixed concrete), and after the solidifiable structure is solidified, the pile yarns 3 of the pile fabric 1 (i.e., the support member) are difficult to pull out (difficult to peel off) from the solidifiable structure, or will not pull out (peel off).
The elastic material of the support member that supports such a solidifiable structure will be described in detail below.

<Elastic material>
The elastic material is generally plate-shaped and has elasticity, and may also have shock and vibration absorbing properties.
The elastic material may be made of, for example, a foam such as ethylene propylene diene rubber (EPDM) or polyurethane, or may be made of polyurethane foam obtained by foaming polyurethane to a predetermined expansion ratio.

The shape of the elastic material is not particularly limited, but for example, in the case where the solidifiable structure is a sleeper, it may be a similar shape to the bottom surface (underside) of the structure (sleeper) in a plan view, but one size smaller, which can be said to make it less likely to protrude from the bottom surface of the structure (sleeper).
There are no particular limitations on the thickness or strength of the elastic material. For example, if the solidifiable structure is a sleeper, the thickness and strength may be such that the elastic material is not crushed or damaged even when the load of a train or other train passing over the rails is applied to the elastic material through the sleeper structure.

For such an elastic material, the pile fabric 1 described above may be fixed to the elastic material by adhering the base fabric 2 to the outer surface (upper outer surface) of a preformed elastic material with an adhesive. In such a case, it can be said that the adhesive impregnates and adheres to the elastic material, such as polyurethane foam, and at the same time, impregnates and adheres to the warp yarns 4 and weft yarns 5 that form the base fabric 2, or the pile yarns 3 that are exposed on the back surface (lower surface) of the base fabric 2.
Alternatively, when the elastic material is polyurethane foam, the pile fabric 1 may be placed in a mold for molding the elastic material and the elastic material may be foam-molded, so that the pile fabric 1 is fixed (adhered) to the outer surface (upper outer surface) of the elastic material by the adhesive strength of the polyurethane.

<Protective materials>
The protective material is a sheet-like material that covers the lower surface (lower side) of the elastic material.
The material of the protective material may be, for example, a nonwoven fabric made of polyolefin-based synthetic resin fibers such as polypropylene (PP) fibers or polyethylene (PE) fibers.

<Method of manufacturing support member>
The method for producing a support member according to the present invention includes the pile fabric 1 produced by the above-mentioned production method and the above-mentioned elastic material.
The manufacturing method of the support member includes a fixing step of fixing the pile fabric 1 to the outer surface of an elastic material so that the base fabric 2 is deformable in response to the elastic deformation of the elastic material, and an embedding step of embedding the pile yarns 3 of the pile fabric 1 in a solidifiable structure.
Alternatively, the method for producing the support member may include a solidification step of embedding the pile yarns 3 of the pile fabric 1 in a solidifiable structure and solidifying the solidifiable structure.

＜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.
The pile fabric 1 may be manufactured by a method other than the manufacturing method including the weaving step S1 and the heat treatment step S2 described above.
Each pile yarn 3 may be secured to a plurality of adjacent weft yarns 5 by passing under the adjacent weft yarns 5 collectively.
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.
The warp yarns 4 may be arranged one by one between adjacent pile yarns 3 in the weft direction.

A synthetic resin such as an acrylic resin adhesive may be applied to the back surface of the base fabric 2 as a back coating (backing). Note that the back surface of the base fabric 2 in Figs. 1 and 2 is not back coated.
As described above, the manufacturing method of the pile fabric 1 may include a backing step of coating the back surface of the base fabric 2 with a synthetic resin such as an acrylic resin adhesive to perform back coating (backing).
In addition, when the backing step, the dissolving step S3 and the separating step S4 are included, the order of the steps in the manufacturing method may be the weaving step S1, the heat treatment step S2 (or the weaving and heat treatment step S1'), the dissolving step S3, the separating step S4 and the backing step, or the weaving step S1, the heat treatment step S2 (or the weaving and heat treatment step S1'), the backing step, the dissolving step S3 and the separating step S4, or the weaving step S1, the dissolving step S3, the heat treatment step S2, the separating step S4 and the backing step, or the manufacturing method may include the backing step. If the dissolving step S3 and the separating step S4 are not included, the order may be weaving step S1, heat treatment step S2 (or weaving/heat treatment step S1'), and backing step; if the backing step is included but either the dissolving step S3 or the separating step S4 is not included, the order may be weaving step S1, heat treatment step S2 (or weaving/heat treatment step S1'), dissolving step S or separating step S4, and backing step, or the order may be weaving step S1, heat treatment step S2 (or weaving/heat treatment step S1'), backing step, dissolving step S or separating step S4, etc.

The pile fabric according to the present invention and the pile fabric produced by the pile fabric manufacturing method have pile yarns 3 (pile loop portions) that are generally rectangular (i.e., not sharp), and therefore can be used for general pile fabric applications such as brushes that come into contact with the human body, the undersides of footwear (such as sandals) in bathrooms, footwear insoles (the components where the pile yarns come into contact with the soles of the feet), hook-and-loop fasteners, and the like, as well as for industrial material applications and other products.
The support member according to the present invention and the support member manufactured by the method for manufacturing the support member can be used for any product, such as industrial material applications, in addition to applications for supporting solidifiable structures.

1 Pile fabric 2 Base fabric 2a Surface base fabric 2b Back base fabric 3 Pile 3' Connecting yarn 4 Warp yarn 5 Weft yarn S1 Weaving process S1' Weaving and heat treatment process S2 Heat treatment process S3 Dissolving process

Claims (9)

A pile fabric in which pile yarns (3) are erected from a base fabric (2),
The base fabric (2) has warp yarns (4) and weft yarns (5),
The pile yarns (3) are anchored to one or more weft yarns (5),
The pile yarn (3) has a tip end side that is substantially U-shaped in side view, and a base end side that is substantially upright with respect to the base fabric (2) in side view,
The pile yarns (3) are provided at predetermined intervals in the weft direction, which is the longitudinal direction of the weft yarns (5),
The pile fabric is for a support member,
The support member has the pile fabric and a substantially plate-shaped elastic material, and is a support member for supporting a solidifiable structure, the pile fabric being characterized in that the base fabric (2) is fixed to the outer surface of the elastic material so as to be deformable in response to elastic deformation of the elastic material, and pile yarns (3) of the pile fabric are embedded in the solidifiable structure . A pile fabric in which pile yarns (3) are erected from a base fabric (2),
The base fabric (2) has warp yarns (4) and weft yarns (5),
The pile yarns (3) are anchored to one or more weft yarns (5),
The pile yarn (3) has a tip end side that is substantially U-shaped in side view, and a base end side that is substantially upright with respect to the base fabric (2) in side view,
The pile yarn (3) is a monofilament yarn, and the single fiber fineness, which is the total fineness, is 20d or more and 3000d or less,
The warp yarn (4) is a multifilament yarn, and has a total fiber size of 20d or more and 1500d or less, and a single fiber size of 1d or more and 600d or less,
The pile fabric is characterized in that the weft yarn (5) is a multifilament yarn, and has a total fiber size of 20d or more and 1500d or less, and a single fiber size of 1d or more and 600d or less . A pile fabric in which pile yarns (3) are erected from a base fabric (2),
The base fabric (2) has warp yarns (4) and weft yarns (5),
The pile yarns (3) are anchored to one or more weft yarns (5),
The pile yarn (3) has a tip end side that is substantially U-shaped in side view, and a base end side that is substantially upright with respect to the base fabric (2) in side view,
The pile yarn (3) is a monofilament yarn, and the number of the pile yarns (3) per inch is 10 or more and 100 or less,
The warp yarns (4) are multifilament yarns, and the number of the warp yarns (4) per inch is 10 or more and 30 or less,
The pile fabric is characterized in that the weft yarn (5) is a multifilament yarn, and the number of the weft yarns (5) per inch is 20 to 250 . A support member for supporting a solidifiable structure, comprising the pile fabric (1) according to any one of claims 1 to 3 and a substantially plate-shaped elastic material,
The pile fabric (1) is fixed to the outer surface of the elastic material so that the base fabric (2) can deform in response to elastic deformation of the elastic material,
A support member, characterized in that the pile yarns (3) of the pile fabric (1) are embedded in the solidifiable structure. A support member for supporting a solidifiable structure, comprising: a pile fabric (1) having pile threads (3) standing up from a base fabric (2), the base fabric (2) having warp threads (4) and weft threads (5), the pile threads (3) being engaged with one or more weft threads (5), the tip side of the pile threads (3) being substantially U-shaped in side view, and the base side being substantially upright with respect to the base fabric (2) in side view, the pile threads (3) having pile fabrics (1) provided at predetermined intervals in the weft direction, which is the longitudinal direction of the weft threads (5), and a substantially plate-shaped elastic material,
The pile fabric (1) is fixed to the outer surface of the elastic material so that the base fabric (2) can deform in response to elastic deformation of the elastic material,
A support member, characterized in that the pile yarns (3) of the pile fabric (1) are embedded in the solidifiable structure. A method for manufacturing a pile fabric in which pile yarns (3) are erected from a base fabric (2),
a weaving step (S1) of connecting a front base fabric (2a) and a back base fabric (2b), each having a warp thread (4) and a weft thread (5), with a connecting thread (3') that is engaged with two or more weft threads (5), thereby weaving the base fabric (2) and the pile thread (3);
After the weaving step (S1), a heat treatment step (S2) is performed to heat-treat the surface base fabric (2a) and/or the back base fabric (2b) ;
The weft yarn (5) contains soluble fibers, and a dissolving step (S3) is provided for dissolving the soluble fibers ,
The connecting yarn (3') is formed into the pile yarn (3) having a tip end side that is substantially U-shaped in side view and a base end side that is substantially upright with respect to the base fabric (2) in side view ,
The pile yarns (3) are provided at predetermined intervals in the weft direction, which is the longitudinal direction of the weft yarns (5),
The pile fabric is for a support member,
the support member has the pile fabric and a substantially plate-shaped elastic material, and supports a solidifiable structure, the pile fabric is fixed to the outer surface of the elastic material so that the base fabric (2) is deformable in response to elastic deformation of the elastic material, and the pile yarns (3) of the pile fabric are embedded in the solidifiable structure . A method for manufacturing a pile fabric in which pile yarns (3) are erected from a base fabric (2),
a weaving step (S1) of connecting a front base fabric (2a) and a back base fabric (2b), each having a warp thread (4) and a weft thread (5), with a connecting thread (3') that is engaged with two or more weft threads (5), thereby weaving the base fabric (2) and the pile thread (3);
After the weaving step (S1), a heat treatment step (S2) is performed to heat-treat the surface base fabric (2a) and/or the back base fabric (2b) ;
The weft yarn (5) contains soluble fibers, and a dissolving step (S3) is provided for dissolving the soluble fibers ,
The connecting yarn (3') is formed into the pile yarn (3) having a tip end side that is substantially U-shaped in side view and a base end side that is substantially upright with respect to the base fabric (2) in side view ,
The pile yarn (3) is a monofilament yarn, and the single fiber fineness, which is the total fineness, is 20d or more and 3000d or less,
The warp yarn (4) is a multifilament yarn, and has a total fiber size of 20d or more and 1500d or less, and a single fiber size of 1d or more and 600d or less,
The method for producing a pile fabric is characterized in that the weft yarn (5) is a multifilament yarn, and has a total fiber size of 20 d or more and 1500 d or less, and a single fiber size of 1 d or more and 600 d or less . A method for manufacturing a pile fabric in which pile yarns (3) are erected from a base fabric (2),
A front base fabric (2a) and a back base fabric (2b) each having a warp thread (4) and a weft thread (5) are connected to each other by a connecting thread (3') which is engaged with two or more weft threads (5), thereby weaving the base fabric (2) and the pile thread (3), and
A weaving and heat treatment step (S1') of heat treating the woven surface base fabric (2a) and/or the woven back base fabric (2b);
The weft yarn (5) contains soluble fibers, and a dissolving step (S3) is provided for dissolving the soluble fibers ,
The connecting yarn (3') is formed into the pile yarn (3) having a tip end side that is substantially U-shaped in side view and a base end side that is substantially upright with respect to the base fabric (2) in side view ,
The pile yarn (3) is a monofilament yarn, and the single fiber fineness, which is the total fineness, is 20d or more and 3000d or less,
The warp yarn (4) is a multifilament yarn, and has a total fiber size of 20d or more and 1500d or less, and a single fiber size of 1d or more and 600d or less,
The method for producing a pile fabric is characterized in that the weft yarn (5) is a multifilament yarn, and has a total fiber size of 20 d or more and 1500 d or less, and a single fiber size of 1 d or more and 600 d or less . A method for manufacturing a support member for supporting a solidifiable structure, the support member having a pile fabric (1) manufactured by the manufacturing method according to any one of claims 6 to 8 and a substantially plate-shaped elastic material, comprising the steps of:
a fixing step of fixing the pile fabric (1) to an outer surface of the elastic material such that the base fabric (2) is deformable in response to elastic deformation of the elastic material;
A method for manufacturing a support member, comprising a step of embedding pile yarns (3) of the pile fabric (1) in the solidifiable structure.

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