JP2018178324A - Pile fabric and production method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a pile fabric that decreases fastness as much as possible and improves flexibility and air permeability.SOLUTION: Each time three weft yarns are inserted into a fabric, the fabric produces piles on the front and back of the fabric. A plurality of pile warp yarns and a plurality of ply warp yarns are alternately arranged in the warp direction. The pile fabric comprises a first texture formed by 3n weft yarns, 2 pile warp yarns and 2 ply warp yarns and a second texture formed by 6 weft yarns, 2 pile warp yarns and 2 ply warp yarns. The pile warp yarns and the ply warp yarns of the first texture are woven in a pair of the face and reverse floating/sinking condition with respect to weft yarns to form the 2/1 structure. In the second texture, 2 pile warp yarns are woven in a pair of the face and reverse floating/sinking condition with respect to 6 weft yarns to form the 2/1 structure. At least one ply warp yarn forms a floating structure with respect to a continuous 3 weft yarns of 6 weft yarns, and ply warp yarns that do not form a floating structure are woven to form the 2/1 structure.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a pile fabric and a method of manufacturing the same.

A pile fabric is a fabric formed by a pile layer having a plurality of Rana (loop) -like piles projecting on the surface and a ground layer which is a base fabric for holding the pile layer, and has flexibility, touch, and ventilation. Excellent in water resistance and water absorption.
For this reason, pile fabrics are conventionally used in various situations, and for example, bath towels, sports towels, face towels, etc. have been used in various ways depending on the size.

  In addition, the pile fabric is woven through a specific process for making a structure with a pile warp forming the pile layer, a ground warp forming the ground layer, and a weft, and causing the pile to protrude on the surface called terry motion. .

In addition, the main factors that determine the properties of the pile fabric include the number of pics and the number of weave points by wefts and ground warps.
The pic number is the number of weft yarns used to form one pile, and the density of the pile per unit area changes according to the size of the pic number. Ordinary pile fabric is woven with 3 pic organization.
A weave point is a point at which wefts and warps intersect. For example, a single warp crosses over m wefts and then sinks under n wefts. In the case of repetition, such a weave relation between wefts and warps is called m / n weave, and the fastness of the fabric changes depending on the number of weave points between wefts and ground warps. Conventional pile fabrics are woven in 2/1 organization.

  Here, with reference to (a) a magnified cross-sectional view and (b) a woven structure diagram in a partial structure of a conventional pile fabric woven with 2 pics and a 2/1 structure of a pile warp and a ground warp, FIG. Show. In the warp enlarged cross-sectional view, the pile warp is indicated by a solid line, and the ground warp is indicated by a dotted line. In FIG. 6 (a), the left side is the front side, the right side is the back side, and the conventional pile fabric has a front pile warp P1 for putting the pile on the front, a back pile warp P2 for putting the pile on the back, A ground warp G1 for holding the pile warp P1 and a ground warp G2 for holding the back pile warp P2 are provided. The weave structure diagram is a diagram showing the vertical relationship between each weft and each warp using a grid, and it is possible to grasp how each warp is woven into the weft. In FIG. 6 (b), G1, P1, G2 and P2 are shown in order from the leftmost column in the floating state, and when the warp is exposed above the weft, ie, on the surface, the white circle In the case where it is shown below the weft, i.e. on the reverse side, it is shown as a blank grid.

  Several pile fabrics that have been devised with regard to the above-mentioned pic numbers and texture points have been proposed.

  In Patent Document 1, a pile warp and a ground warp are alternately arranged in the warp direction, and a plurality of back-raised wefts and a plurality of pile wefts are alternately arranged in the warp and crossed with the weft. A woven fabric is described in which a back weft is raised and a pile structure is woven on the other side.

  Patent Document 2 describes a pile fabric which has a 5 pic organization and in which a ground warp is regularly woven in a 3/2 organization with respect to a weft, in an attempt to prevent pile omission.

  Patent Document 3 describes a pile fabric suitable for curtain fabrics and clothing fabrics, in which ground warp yarns are regularly woven in 3/3 or 5/5 with respect to wefts.

Unexamined-Japanese-Patent No. 1997-324341 Patent No. 2719587 JP, 2015-203158, A

  However, as described in Patent Document 1 and Patent Document 2, when the number of pics increases, the density of the pile per unit area decreases, and the properties such as flexibility and touch deteriorate. In addition, since the number of weft yarns per pile increases, manufacturing efficiency is degraded.

  In addition, as in Patent Document 3, when the overall textural relationship (m / n texture) of the ground warp and weft is woven as m ≧ 3 and n ≧ 3, it is assumed that there are many so-called "floating textures", The ability of the ground layer to hold the pile layer is reduced. Therefore, the formation of the pile becomes difficult, and the robustness to external force such as friction decreases as the whole fabric.

  The present invention has been made in view of the above-described actual situation, and an object of the present invention is to provide a pile fabric in which the decrease in the fastness is minimized and the flexibility and the air permeability are improved.

In order to solve the above problems, the present invention is
A pile fabric having a pile layer and a ground layer for holding the pile layer, wherein the pile fabric has a three-pic texture, and piles out on both sides each time three wefts are inserted,
A plurality of pile warps used for forming a pile layer in a warp direction and a plurality of ground warps used for forming a ground layer are alternately arranged;
A first structure formed by the weft 3n (n is an integer of 1 or more), two pile warps, and two ground warps;
A second structure formed of six weft yarns, two pile warp yarns, and two ground warp yarns, and in the first structure, the two pile warp yarns and the two ground warp yarns are: The three-n weft yarns are woven by being woven in a 2/1 structure in a state of ups and downs of a pair of front and back respectively
In the second structure, two of the pile warps are woven by being woven in a 2/1 structure in a state of ups and downs with respect to the six wefts, and at least one of the ground warps is the weft The ground warp yarn which is woven to form a floating structure for three consecutive wefts of six and does not form a floating structure is structured by weaving in a 2/1 structure,
It is characterized in that a predetermined number of tissues in which the first structure and the second structure are alternately arranged in the warp direction are arranged in the weft direction.

According to the present invention, it is possible to partially interweave a floating structure such as a 3/3 structure or a 3/1 structure while appropriately weaving a plurality of ground warps to the weft in a 2/1 structure regularly. . As a result, the pile holding power is reduced for the 3/3 structure and the 3/1 structure of the ground layer. That is, according to the present invention, since the repulsive force of the pile is partially reduced, it is possible to improve the flexibility as compared with the whole of the pile fabric woven with a 2/1 structure.
In addition, since the floating structure is partially woven, it is possible to minimize the decrease in the robustness of the entire pile fabric.

  Furthermore, since the number of weave points between the ground warp and weft decreases, air permeability is improved, and quick drying can be improved as compared to the whole of the pile fabric woven with a 2/1 structure. .

A preferred embodiment of the present invention is characterized in that the second structure adjacent in the weft direction is disposed at an interval of three or more wefts.
By weaving in such a configuration, it is possible to achieve uniform drying of the entire pile fabric because the floating structure formed by the second structure is not concentrated at a specific location but distributed. Become.

The present invention is a method for producing a pile fabric of 3pic texture, comprising a pile layer and a ground layer for holding the pile layer, and piling out on both the front and back sides every time three wefts are inserted,
Alternately arranging a plurality of pile warps used for forming a pile layer in a warp direction and a plurality of ground warps used for forming a ground layer,
Using 2 wefts 3 n (n is an integer of 1 or more), 2 pile warps, and 2 ground warps, 2 pile warps and 2 ground warps relative to 3 n wefts The first tissue is formed by weaving in a pair of upper and lower floating and sinking states, respectively.
Using the six wefts, the two pile warps, and the two ground warp yarns, the two pile warps are woven in a 2/1 structure with a pair of upper and lower floats with respect to the six wefts. Weaving at least one of the ground warps so as to form a floating structure with respect to three consecutive wefts of the six wefts, wherein the ground warp does not form a floating structure is a 2/1 structure Form a second structure by weaving
It is characterized in that weaving is performed by arranging a predetermined number of tissues in which the first structure and the second structure are alternately arranged in a predetermined number in the warp direction, in the weft direction.

  According to the present invention, it is possible to provide a pile fabric with minimized reduction in fastness and improved flexibility and air permeability.

The partial structure of the pile fabric which concerns on embodiment of this invention is shown, Comprising: (a) is a transmission enlarged sectional view, (b) is a weave structure | tissue figure. It is a warp enlarged sectional view showing the state immediately before the terry motion of the pile fabric according to the embodiment of the present invention, wherein (a) is a warp enlarged sectional view to weft yarns d1 to e3 in FIG. It is a warp enlarged sectional view to weft a1-b3. It is one perfect organization figure of a pile textile concerning an embodiment of the present invention. The partial structure of the pile fabric which concerns on embodiment of this invention is shown, Comprising: (a) is a transmission enlarged sectional view, (b) is a weave structure | tissue figure. It is a figure which shows the result of test 1, Comprising: (a) is a figure which shows a time-dependent change of weight from the dry start time to the dry finish time, (b) is a weight from 150 dry start to dry finish in (a). It is a figure which expands and shows a time-dependent change of. The partial structure | tissue of the conventional pile fabric is shown, Comprising: (a) is a transmission enlarged sectional view, (b) is a weave structure | tissue diagram.

  Hereinafter, a pile fabric according to an embodiment of the present invention will be described using the drawings. The embodiment described below is an example of the present invention, and the present invention is not limited to the following embodiment.

In FIG. 1A, the left side is the front side, the right side is the back side, and the pile fabric according to the present embodiment is a front pile warp P1 for putting out the pile on the front side and a back pile warp P2 for putting out the pile on the back side. And a ground warp G1 for holding the front pile warp P1 and a ground warp G2 for holding the back pile warp P2. The pile warp is indicated by a solid line, and the ground warp is indicated by a dotted line.
Moreover, the pile fabric according to the present embodiment is a 3 pic fabric, and includes wefts a to e grouped into three, all of which are indicated by white circles. For example, the weft a is distinguished from the lower one in the order of the first weft a1, the second weft a2, and the third weft a3.

  First, the floating and sinking states of the front pile warp P1 and the back pile warp P2 will be described. The front pile warp P1 sinks from between the first weft a1 and the second weft a2 to the back of the second weft a2, and floats out from between the second weft a2 and the third weft a3 to the front, and this third weft a3 and It flies between the next first weft b1 and sinks from the first weft b1 and the second weft b2 to the back side, and is repeatedly woven into the wefts a to e. The back pile warp P2 is woven into the wefts a to e in a float-reversed state opposite to the front pile warp P1 so as to form a front pile warp P1 on the front and back.

  Next, the floating and sinking states of the ground warp yarn G1 and the ground warp yarn G2 will be described. The ground warp yarn G1 flies between the first weft a1 and the second weft a2 with respect to the wefts a to c and sinks from the second weft a2 and the third weft a3 to the back side, and the third weft a3 and the next Fly between the first weft b1 and the second weft b2 and float from the second weft b2 and the third weft b3 to the front side, and between the third weft b3 and the next first weft c1 and the second weft c2 It flies and sinks from the second weft c2 to the third weft c3 to the back side, and is woven so as to float from the third weft c3 to the next first weft d1 to the front side. Then, with respect to the weft d, it flies between the first weft d1 and the second weft d2 and sinks from the second weft d2 and the third weft d3 to the back side, and the third weft d3 and the next first weft e1. It floats to the front side from between, and it weaves by repeating the same float and sink state also to the weft e. The ground warp yarn G2 is woven into the wefts a to e in a float-reversed state opposite to that of the ground warp yarn G1 so as to be paired with the ground warp yarn G1.

  FIG. 1 (b) is a weave diagram of the woven fabric woven as shown in FIG. 1 (a). Weft yarns c1 to e3 are the first structure 1 organized similarly to the conventional pile fabric shown in FIG. 6, and all four warp yarns (P1, P2, G1, G2) are regularly 2/1. Interwoven in the organization. Further, wefts a1 to b3 are the second texture 2, and a float texture W is formed on the wefts a3 to b2 of the ground warp yarn G1 and the ground warp yarn G2, respectively.

  Further, in FIG. 1 (b), the floated structure W is also formed in the wefts b3 to c2 by the combination of the first structure 1 and the second structure 2 and is woven in the 3/3 structure on the wefts a3 to c2. It is a form.

  Next, with reference to FIG. 2, the reason why the pile holding force is reduced only at the portion where the floating structure is formed will be described.

  When weft d3 is moved to the left from the state of FIG. 2 (a), crossing points of ground warp G1 and ground warp G2 are formed between weft d3 and weft e1, so weft e1 and weft e2 Is compressed in the vertical direction by the ground warp yarn G1 and the ground warp yarn G2, and receives a force in the direction of moving to the right. Next, by moving the weft e3 to the left, the weft e1 and weft e2 and the weft e3 are pressed against each other, and the weft e1 and weft e2 and the weft e2 and weft e3 are inserted between them. The pile warp P1 and the back pile warp P2 are strongly sandwiched. By this series of operations, piles held on the ground warp yarn G1 and the ground warp yarn G2 are formed one on each of the front and back.

  On the other hand, when weft a3 is moved to the left from the state of FIG. 2 (b), weft b1 and weft b2 are not formed because crossing points of ground warp G1 and ground warp G2 are not formed. The weft b2 does not receive force in the direction of moving to the right. As a result, even if the weft b3 is moved to the left, compared with the state shown in FIG. 2A, the forces of the weft b1 and weft b2 and the weft b3 are mutually reduced, resulting in the weft b1. The holding power of the front pile warp P1 and the back pile warp P2 due to b3 is reduced. In addition, since the position of the weft a3 is not fixed, the holding power of the front pile warp P1 and the back pile warp P2 inserted between the weft a2 and the weft a3 also decreases.

  FIG. 3 (a) is a complete tissue diagram using the first tissue 1 and the second tissue 2 described with reference to FIG. One grid represents a structure formed of 4 warps × 3 wefts, and two grids adjacent in the warp direction, which are filled with diagonal lines, are the second structures 2. Also, one blank cell is the first tissue 1 when n = 1. FIG. 3 (b) shows the correspondence between each square in FIG. 3 (a) and the texture chart.

  In the warp direction, a tissue in which a first tissue 1 of n = 6 and one second tissue 2 are one unit is repeatedly arranged, and eight of the tissues are arranged in the weft direction. Further, the second structure 2 adjacent in the weft direction is disposed in the warp direction at an interval of one blank grid.

  By arranging a plurality of complete tissues thus organized in the warp direction and the weft direction, various pile fabrics such as bath towels, sports towels, face towels, etc. are woven.

  FIG. 4 is a partial organization chart organized by a weaving method different from the partial organization chart shown in FIG. The floating and sinking states of the front pile warp P1 and the back pile warp P2 are the same as in the partial structure diagram shown in FIG. 1, but the floating and sinking states of the ground warp G1 and the ground warp G2 are different.

  The ground warp yarn G1 sinks from the first weft yarn a1 and the second weft yarn a2 to the back side with respect to the weft yarns a to b, and jumps between the second weft yarn a2 and the third weft yarn a3 and the next first weft yarn b1 Float from the first weft b1 to the second weft b2 to the front side, sink from the second weft b2 to the third weft b3 to the back side, float to the front from the third weft b3 to the next first weft c1 To be woven. Then, with respect to the weft c, it flies between the first weft c1 and the second weft c2 and sinks from the second weft c2 and the third weft c3 to the back side, and the third weft c3 and the next first weft d1. It floats to the front side from between, and it weaves by repeating the same float and sink state also to weft d-e.

  The ground warp G2 flies between the first weft a1 and the second weft a2 with respect to the weft a, and floats out from between the second weft a2 and the third weft a3 to the front side, and the third weft a3 and the next second It sinks from the side of the single weft yarn b1 to the back side, and is woven by repeating the same float and sink state for the weft yarns b to c. Then, with respect to the wefts d to e, it floats out from between the first weft d1 and the second weft d2 to the front side, and flies between the second weft d2 and the third weft d3 and the next first weft e1. Sinks from the weft yarn e1 to the second weft e2 to the back side, floats from the second weft e2 to the third weft b3 to the front side, and from the third weft e3 to the next first weft f1 (not shown) to the back side It sinks into it.

As described above, by weaving four warps (P1, P2, G1, G2), as shown in FIG. 4 (b), wefts a1 to b3 form the second structure 2 and wefts c1 to c3. The second structure 2 is formed by the first structure 1 and the wefts d1 to e3.
In the second structure 2 of the weft yarns a1 to b3, a floating structure W (3/1 structure) is formed only on the ground warp yarn G1 and on the weft yarns a2 to b2. In the second structure 2 of the weft yarns d1 to e3, a floated structure W (3/1 structure) is formed only on the ground warp yarn G2 and in the weft yarns d2 to e2.

  Next, Tests 1 and 2 were conducted to compare the difference in air permeability between the pile fabric woven using the present invention and the pile fabric woven using the conventional technique.

Specifically, it is a pile fabric of 340 × 800 mm woven using one complete structure of the present invention shown in FIG. 3 and using a 20-count single cotton yarn for the front pile warp P1 and the back pile warp P2. A 340 × 800 mm pile fabric woven using the “Invention 1” and the “Invention 2” using a single 16th-count cotton yarn and the partial structure of the conventional pile fabric shown in FIG. Uses a total of 4 types of pile fabrics: “Conventional product 1” using 20-count single cotton yarn for front pile warp P1 and back-pile warp P2 and “conventional product 2” using 16 single-thread cotton yarn The test was done.
The count is a unit that represents the thickness of the yarn, and the smaller the number, the thicker the yarn.
In all four types of pile fabrics, cotton yarn of 30th double yarn is used for ground warp, cotton yarn of 20th single yarn is used for weft, and the weft density (the number of wefts per inch) is 52. .

<Test 1>
The four types of pile fabrics described above are placed in a washing machine once, subjected to washing and dewatering steps, arranged so that they do not overlap each other on the floor surface, and dried by applying a fan from the top. The weight of each pile fabric is then measured every 30 minutes and the drying process is continued until the weight of all pile fabrics is constant.

  Tables 1 and 2 show the results of the above test. Table 1 shows the change over time in weight due to drying of each pile fabric in a gram display. Table 2 shows the corrected values by calculating the ratio of the amount of water contained in each pile fabric to the weight of each pile fabric, and assuming that the ratio at the start of drying (0 minutes) is 100%. . The amount of water contained in each pile fabric was calculated by subtracting the weight of each pile fabric at the completion of the dewatering process from the values in Table 1. Moreover, the result of Table 2 was plotted on the graph and FIG. 5 was obtained.

As shown in FIG. 5 (a), since the slope of the graph decreases across the drying time of 150 minutes, the pile layer on the surface is dried in the drying time of 150 minutes, and thereafter the ground layer is dried. It is thought that it was done.
From FIG. 5 (b), comparing “Invention 1” and “Conventional Product 1”, and “Invention 2” and “Conventional Product 1”, which are the same condition except tissue, until the weight becomes constant respectively Although the inclinations are similar, the weight of "Invention 1" and "Invention 2" is constant at a drying time of 210 minutes, and the "conventional product 1" and "conventional product 2" have a drying time of 270 minutes. The weight is constant. That is, in Test 1, "Invention 1" and "Invention 2", which are pile fabrics woven using one complete structure of the present invention, are "conventional products 1" and "conventional products 2" which are conventional pile fabrics. It is considered that the drying is completed about one hour earlier than "." This suggests that the "present invention 1" and the "present invention 2" have higher air permeability than the "conventional product 1" and the "conventional product 2".

<Test 2>
The air permeability evaluation test based on JIS L 1096 A method (Frazil type method) was performed on the above four types of pile fabrics. The results are shown in Table 3.

The air permeability is evaluated by the air permeability represented by (cm 3 / (cm 2 · s)), and this unit represents "volume of air passing through 1 square centimeter per second". That is, the larger the value of the air permeability, the higher the air permeability.
In Table 3, the values of the air permeability of “Invention 1” and “Conventional product 1” are 56.6 and 39.8 respectively, and “Invention 1” is approximately equal to “Conventional product 1”. It can be seen that the air permeability is improved by 40%. In addition, the values of air permeability of “Invention 2” and “Conventional product 2” are 63.0 and 48.4, respectively, and “Invention 2” is about 30% compared to “Conventional product 2”. It can be seen that the breathability is improved.

According to this embodiment, while weaving the ground warp yarn G1 and the ground warp yarn G2 regularly to the weft in 2/1 structure, partially weave the floating structure W such as 3/3 structure or 3/1 structure as appropriate As a result, the pile holding power is lowered for the 3/3 structure and the 3/1 structure of the ground layer. As a result, since the repulsive force of the pile partially decreases, it is possible to improve the flexibility as compared to the whole of the pile fabric woven with a 2/1 structure.
In addition, since the floating structure W is partially woven, it is possible to minimize the decrease in the robustness of the entire pile fabric.

  Furthermore, since the weave points of the ground warp yarn G1 and the ground warp yarn G2 and the weft yarn are reduced, the air permeability is improved, and quick drying is improved as compared with the whole of the pile fabric woven in 2/1 structure. It becomes possible.

  In addition, since the second structure 2 adjacent in the weft direction is disposed at an interval of three wefts, the floating structure W formed by the second structure 2 is not concentrated at a specific location, but dispersed. Because of this arrangement, it is possible to achieve uniform drying of the entire pile fabric.

  The shapes, dimensions, and the like of the constituent members shown in the embodiment are merely examples, and various changes can be made based on design requirements and the like.

1 first structure 2 second structure P1 surface pile warp P2 back pile warp G1, G2 ground warp W floating structure a1, b1, c1, d1, e1 first weft a2, b2, c2, d2, e2 second weft a3, b3, c3, d3, e3 third weft

Claims (3)

A pile fabric having a pile layer and a ground layer for holding the pile layer, wherein the pile fabric has a three-pic texture, and piles out on both sides each time three wefts are inserted,
A plurality of pile warps used for forming a pile layer in a warp direction and a plurality of ground warps used for forming a ground layer are alternately arranged;
A first structure formed by the weft 3n (n is an integer of 1 or more), two pile warps, and two ground warps;
A second structure formed of six weft yarns, two pile warp yarns, and two ground warp yarns, and in the first structure, the two pile warp yarns and the two ground warp yarns are: The three-n weft yarns are woven by being woven in a 2/1 structure in a state of ups and downs of a pair of front and back respectively
In the second structure, two of the pile warps are woven by being woven in a 2/1 structure in a state of ups and downs with respect to the six wefts, and at least one of the ground warps is the weft The ground warp yarn which is woven to form a floating structure for three consecutive wefts of six and does not form a floating structure is structured by weaving in a 2/1 structure,
A pile fabric in which a predetermined number of tissues in which the first structure and the second structure are alternately arranged in the warp direction are arranged in the weft direction.   The pile fabric according to claim 1, wherein the second structure adjacent in the weft direction is disposed at an interval of three or more wefts. A method for producing a pile fabric of 3pic texture, comprising a pile layer and a ground layer for holding the pile layer, and piling out on both sides of the front and back sides whenever three wefts are inserted,
Alternately arranging a plurality of pile warps used for forming a pile layer in a warp direction and a plurality of ground warps used for forming a ground layer,
Using 2 wefts 3 n (n is an integer of 1 or more), 2 pile warps, and 2 ground warps, 2 pile warps and 2 ground warps relative to 3 n wefts The first tissue is formed by weaving in a 2/1 structure, each in a floating / sinking state of a pair of front and back,
Using the six wefts, the two pile warps, and the two ground warp yarns, the two pile warps are woven in a 2/1 structure with the front and back of the six wefts in an ups and downs state Weaving at least one of the ground warps so as to form a floating structure with respect to three consecutive wefts of the six wefts and forming the floating warp without forming a floating structure in a 2/1 structure Form a second structure by weaving
A method of manufacturing a pile fabric, comprising: arranging a predetermined number of the first tissue and the second tissue alternately arranged in the warp direction with a predetermined number in the weft direction.