JPS5817303B2 - Seat material for vehicles, etc. - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a pile sheet material suitable for use in vehicle seats, car cloaks, upholstery, wall coverings, linings, etc., which can be particularly dyed by piece dyeing, and which is novel in texture and appearance. It is about pile sheet fabric that creates a sense of sensation.

Traditionally, pile fabrics have been produced using a flocking process in which short fibers are glued to the base fabric and flocked, pile threads are pled during knitting to make the pile appear, and fibers with different heat shrinkage are used to create long and short pile fabrics. It is made by various methods, such as forming a pile yarn or weaving two pieces of fabric together with pile yarn and cutting from the center. Acrylic synthetic fibers are mostly produced, and many methods are used to create flat knitting with ground knitting yarn using a circular knitting machine, and at the same time entwining long pile yarns in the stitches to reveal the pile on the surface. ing.

However, since the pile formed by such a method only has its base hooked across the stitches, it often falls off, especially when used for products that require abrasion resistance, such as vehicle seats. However, the durability was poor and the value of the product was impaired, creating a situation where it could not be put to practical use.

Of course, when plating pile yarn as a pile knitted fabric from the beginning, even though there is no risk of shedding as described above, there is a limit to the pile length, and it is technically difficult to produce so-called high piles from the viewpoint of production efficiency. However, it has hardly reached the stage of practical use.

In particular, it is desirable to use polyamide or polyester fibers in recent vehicle seats from the standpoint of abrasion resistance, and pile fabrics using these fibers are being developed instead of pile fabrics that use general acrylic fibers. There is a lot of research going on.

In view of the above-mentioned circumstances and in immediate response to the demands of the industry, the present invention aims to provide a highly durable high pile fabric that is based on the use of polyamide or polyester fibers and is free from the fear of fibers falling off. It is.

That is, the feature of the present invention is that it is made of polyamide or polyester synthetic fibers or a mixture of both, and has different numbers of crimp, with some having a small number of crimp of 12 or less per inch. Fibers containing fibers of The reason is that the fear of fibers falling off when worn is eliminated.

Hereinafter, the specific contents of the present invention will be further explained in detail one by one.

The attached drawings, FIGS. 1 to 6 show each side of the pile fabric according to the present invention, and FIGS. 1 and 2 show the pile fabric in which a loop pile 2 is formed on one side of the knitted fabric 1, and Figures 3 and 4 show pile fabrics in which loop piles 2, napped piles, and twill 3 are alternately formed on one side of the knitted fabric 1, and Figures 5 and 6 show pile fabrics in which only napped piles 3 are formed on one side of the knitted fabric. Different pile fabrics are shown in the figure.

In each of these illustrated examples, the intertwined structure of the pile formed on the surface of the knitted fabric 1 is as shown in enlarged views in FIGS. The pile-constituting fiber bundles 5 are similarly plied into a loop and held in a knitted state to form a pile on the knitted surface.

In this case, the yarns 4 constituting the knitted fabric 1 into which pile yarns are knitted on each side shown in the figure include polyamide synthetic fibers,
Any fiber yarn can be used, such as filaments of any fibers such as polyester synthetic fibers and recycled cellulose fibers, or spun yarns made of these fibers alone or in combination.
The pile-forming fibers that are knitted into the stitches of the knitted fabric in a U-shape include polyamide synthetic fibers and polyester synthetic fibers that have good abrasion resistance, such as in vehicle seats. Either short fibers or long fibers can be used, but these pile yarn constituent fibers are usually aligned,
It has a focused shape.

Of course, it goes without saying that it is preferable to use polyamide or polyester synthetic fibers as the knitted fabric constituent yarns 4, similar to the pile constituent fiber bundles 5.

In addition, the polyamide-based or polyester-based synthetic fibers that make up the pile include those that form the pile or standing hair, and the fibers that form the thin and short downy hairs that grow in a curled state at the base of the hair. At least two types of short fibers, long and short, may be used as a component, and the fibers used may be suitably thin and flat irregular cross-section fibers, or other irregular cross-section fibers such as lens-shaped, crescent-shaped, or dyeable. It is also desirable to use fibers with different properties, such as gender, as part or all of the fabric, which allows pile fabrics to be used as various ornaments.

Furthermore, both polyamide fibers and polyester fibers have less crimp than conventional cases, and it is preferable to mix 12 or less fibers per inch or mix a copolymer composition to create a porous fiber form. The most common average cut length of the short fibers constituting the pile is about 38 to 51 mm.

In particular, 1 part per inch in 2 parts as pile-constituting fibers.
Including fibers with a small number of crimps of 2 or less means that when they are knitted together with other fibers with several crimps and long and short piles are made to appear on the knitted surface through subsequent processing, it becomes a seal-like long pile. It is effective not only for its appearance but also for creating a soft feel on the pile surface, giving it a luxurious feel as a sheet material.

When the above-mentioned pile fabric is used as a vehicle seat, after it has been manufactured, it is maintained at 70°C to 110°C using general circulation dyeing methods such as wince dyeing and circular dyeing. It is dyed and colored by immersing it in a dye bath.

Of course, known dyes selected for each fiber are used, such as acid dyes for polyamide synthetic fibers and disperse dyes for polyester fibers, and precipitation prevention is applied as needed during dyeing. Agents are used in combination.

However, the dyeing means is not limited to this, and it goes without saying that any suitable post-dyeing method can be applied.

Also, oiling is performed as necessary after piece dyeing.

In order to further improve the texture of the piece-dyed pile fabric made in this way after finishing, the overfeed rate in the warp direction is increased by 2 in the tentering process during drying after dyeing.
It is fed at a rate of 5 to 35% and finishing processing is performed.

In this case, when overfeeding is carried out in conventional general width adjustment after dyeing of knitted fabrics, an overfeed rate of about 7 to 8% is adopted at most, and if it is higher than this, the knitted fabric However, in the present invention, it is possible to perform tentering processing at a rate of 25 to 35%, which is higher than the conventional overfeed rate.

This is because the pile is relatively long compared to conventional woven piles, and unlike double knits, it has piles or raised piles knitted together in the stitch loops, which increases the thickness of the entire fabric. This is also the result of investigating the degree of finishing from the relationship between this thickness and the feeding speed during tentering.

The sheet material of the present invention is produced based on each of the above requirements, but since it is a pile cloth, backing treatment with acrylic ester or the like is performed as necessary to fix the base of the pile.

If this back processing is carried out before dyeing, the washing resistance will be poor and the back resin will also be dyed, which is undesirable; therefore, it is usually carried out after dyeing in order to minimize the amount of cotton shedding during dyeing.

In addition to the above-mentioned treatments, as a pile cloth finishing operation, a poly-lashing process in which the pile or raised pile is stretched between heating rolls, and a shearing process are also applied at any time.

After dyeing and tentering, polylash processing is usually carried out by passing between multiple stages of heating rolls that gradually reduce the temperature, while shearing is carried out before or after dyeing in order to keep the pile approximately uniform. This is carried out once to several times at appropriate times, and the pile length is adjusted to a required length, for example, about 15 inches or less.

The piece-dyed pile fabric obtained as described above has a novel pile formation structure, and by satisfying each of the conditions, it can be dyed with a wince etc. of pile fabric, which has not been done in the past, and can be used in various ways. Not only can you obtain a multicolored pattern with a wide variety of variations, but you can also provide pile products with less shrinkage after washing due to the piece-dyed effect. It is possible to obtain a piece-dyed pile fabric that has a texture and appearance different from the ground, and is wear-resistant and stiff.

In particular, the above-mentioned pile fabric contains fibers with a small number of crimps that are interlaced in the stitches in the pile layer, thereby forming a seal-like appearance that stretches against the long pile on the surface of the pile layer, making the pile surface glossy and shiny. The outside has a strong and unusual texture,
1 of the pile fabric of the present invention, which has both abrasion resistance and reduced cotton shedding rate.
It offers two features.

In particular, the use of polyamide or polyester synthetic fibers meets the current trend for various interior parts, including vehicle seats and car mats, which require the highest wear resistance, and is attracting attention for its novelty and solidity, and is improving productivity. Combined with this, it is a pile sheet material that is expected to have a wide range of uses.

Next, examples of the present invention are listed.

EXAMPLE Using a polyamide synthetic fiber (trade name: Leona, manufactured by Asahi Kasei Kogyo Co., Ltd.) as described below, bi-pile knitting with loop piles on the knitted surface was carried out using an 8-fiber, 9-knit sliver knitting machine.

Ground knitting yarn: Nylon 210d 100% loop pile: Polyamide fiber (product name Leona Asahi Kasei Kogyo Co., Ltd.) 10dX51mm 50% Leona 18dX5]mi 50% The fabric width of the plane where the above gray fabric was cut is 145CrrL,
It was 6 m long and weighed 6.8 kg.

The above greige was then washed with acid dye and acetic acid (ph3).
．． Dyeing was carried out using a dye bath consisting of 5).

In this case, the temperature of the gray cloth is gradually raised using the above dye bath, and
℃ and continued for an additional 3.0 minutes.

After that, Shindesu TA460-15 (manufactured by Matsumoto Yushi) 3%
The solution was applied to the inside of the pile, softened at 45°C for 20 minutes, dehydrated using a drying machine, and placed in a dry carpet machine.

The dry carpet machine has a width of 102 cr I'L, a pin width of 150 °, an overfeed rate of 27%, and a 4 m width at a temperature of 120 °C.
Finished at a speed of /mvL.

The pile fabric thus obtained was spread with a pin width of 135 mm, and the back was treated with a resin processing liquid consisting of % acrylic ester and % water.
Subsequently, poly lacquer processing was performed.

The pile cloth that has gone through each of the above processes is then placed in a tumbler for 110
℃ for 60 minutes, slowly cooled for 15 minutes, and then taken out. The resulting pile fabric had a good dyeing effect, with no visible sagging in the pile fibers, and had a voluminous feel. During this period, no pile fibers fell out, and almost no decrease in area weight was observed.

Example 2' A blended yarn of Poly King Stell/Rayon 65/35 was used as the ground knitting yarn, and Tetron (trade name, manufactured by Yojin) 1 was used as the pile fiber.
2dX38 order, 40%, flat section Tetron 7dx387
A sliver consisting of 30% ILTL and 30% Tetoron was formed, and raised bi-pile knitting was performed using the same sliver knitting machine as in Example 1.

Is this gray fabric weight 430? /M with a width of 120cIrL and a length of 20m, jarring was performed three times and cut into 8 lengths.

This fabric was wince dyed for polyester dyeing using a dye bath composition consisting of a disperse dye, a carrier, a dispersant, and sodium phosphate, and then subjected to a tentering process using a dry carpet machine.

Note that the tentering conditions were as follows. pin width
150CrfL Overfeed rate 27% While feeding the pile fabric that has gone through the above process with a pin width of 150CIrL, it is 12%
Dry back processing finish is performed at 0℃, and hair splitting (P
I40 P 1so ) (PI30 PI20
) (PI20 P, to ) - hair division = (PI20
PIIO)-(Ploo P2O)-finished by shearing.

Here, (PI40 PI30) indicates the case where the respective heating temperatures of the pair of rolls are 140°C and 130°C.

The final width of the pile fabric manufactured in this way is 130
The length of CrIL was 17.8 m, the basis weight was 450 P/M, and the fibers did not fall off and the texture was very good.

[Brief explanation of the drawing]

FIGS. 1 and 2 are a perspective overview view and a side view schematic diagram showing the vertical direction of the pile fabric according to the present invention, and FIGS. 3 and 4 are a perspective overview view and side view schematic diagram showing other examples of the pile fabric according to the present invention. A schematic diagram, FIGS. 5 and 6 are perspective and side schematic views showing other examples of the pile fabric according to the present invention, and FIGS. 7 and 8 are diagrams showing each side of the stitch hooking mode of the pile constituent fibers. FIG.

Claims (1)

[Claims] 1 A pile fabric with a pile layer formed on a base fabric surface, the base fabric being a knitted fabric made of ordinary stockinette fibers, and the pile layer being made of polyamide or polyester fibers, or both. is composed of bundles of fibers of a predetermined length, with different numbers of crimps, and some of which include fibers with a small number of crimps of 12 or less per inch, and
The fiber bundle base is spliced in a U-shape to the stitch loops of the knitted fabric and locked by knitting, forming at least two types of bundled fiber piles, long and short, on the base fabric surface. Seat material for vehicles, etc.