US20080020173A1

US20080020173A1 - Polyester Pile Fabric Having Excellent Soft Hand, Abrasion Resistance And Bathochromic Effect

Info

Publication number: US20080020173A1
Application number: US11/628,361
Authority: US
Inventors: Migifumi Fukunaga; Hirokazu Hayashi
Original assignee: Teijin Fibers Ltd
Current assignee: Teijin Frontier Co Ltd
Priority date: 2004-08-06
Filing date: 2005-08-04
Publication date: 2008-01-24
Also published as: KR20070039484A; CN1965118A; TW200609400A; WO2006014020A1; JP2006045731A

Abstract

The pile fabric having a very soft hand, a high abrasion resistance and a good bathochromic effect comprises a ground structure portion constituted from a polyester filament yarns and having a knitted or woven structure and a pile portion comprising polyester filaments knitted or woven into the ground structure portion. The polyester filaments for the pile portion have a flat cross-sectional profile with a flat ratio of 2 to 6, and an individual filament thickness of 0.5 to 1.5 dtex. In the flat cross-sectional profile, least two pairs of mutually opposite concavities (valley portions) are formed.

Description

TECHNICAL FIELD

The present invention relates to a polyester pile fabric having a cut pile layer formed from flat polyester filaments and excellent soft hand, abrasion resistance and bathochromic effect.

BACKGROUND ART

A pile fabric has heretofore been used in a large amount for car sheets, home interiors, office interiors, exhibition hall interiors, clothing, and the like. In particular, pile fabrics have been required to exhibit significantly excellent properties, and various pile fabrics have been proposed.
For example, a pile fabric, the bathochromic effect of which is improved by lowering the content of a delustering agent of the raw yarn for piles and making the size fall in a specific range, has been proposed in Japanese Unexamined Patent Publication (Kokai) No. 7-102445 (Patent Reference 1). Furthermore, a pile fabric, the bathochromic effect of which is improved by using yarns having a necked flat cross-sectional profile as pile filaments, is proposed in Japanese Examined Utility Model Publication (Kokoku) No. 7-40541 (Patent Reference 1) and Japanese Unexamined Patent Publication (Kokai) No. 10-158953. However, although these pile fabrics are excellent in a bathochromic effect, it cannot be said that they have a satisfactory soft hand.
On the other hand, a fabric formed from extremely fine filaments has been known as a fabric having a soft hand (e.g., Japanese Unexamined Patent Publication (Kokai) No. 7-70871). however, when conventional extremely fine filaments are used as the pile fiber, the total filament surface area is increased, and a significant irregular reflection of light takes place to cause the problem that the dyed fabric thus obtained exhibits a whitish color without deepening the color. Moreover, because the pile filaments have a small individual filament thickness, the fabric has the problem that the individual filaments are likely to be broken to lower the abrasion resistance.
As explained above, pile fabrics having high soft hand and abrasion resistance and showing a marked bathochromic effect have not been proposed but are desired.

Patent Reference 1: Japanese Unexamined Patent Publication (Kokai) No. 7-102445
Patent Reference 2: Japanese Examined Utility Model (Kokoku) No. 7-10541
Patent Reference 3: Japanese Unexamined Patent Publication (Kokai) No. 10-158953
Patent Reference 4: Japanese Unexamined Patent Publication (Kokai) No. 7-70871

DISCLOSURE OF THE INVENTION

An object of the present invention is to provide a polyester pile fabric having a very soft hand, excellent abrasion resistance and bathochromic effect, and fiber articles thereof.
As a result of intensively carrying out investigations to achieve the above object, the inventors of the present invention have discovered that a desired pile fabric can be obtained by using polyester filaments yarns having a necked flat cross-sectional profile and a specific individual pile filament thickness. They have further intensively investigated to achieve the present invention.
A polyester pile fabric of the present invention comprises a ground structure portion having a knitted or woven structure formed from polyester filaments yarns, and a pile portion comprising polyester filaments yarns knitted or woven into the ground structure portion,
the pile portion having a cut pile layer formed on one side of the ground structure portion and comprising the polyester fibers,
the polyester fibers from which the pile portion is formed, having a individual fiber thickness of 0.5 to 1.5 dtex and a flat cross-sectional profile,
the flat ratio of the flat cross-sectional profile represented by a ratio B/C1 wherein B represents the maximum width of the cross-sectional profile, and C1 is the maximum thickness of the profile in the direction at right angles to the maximum width direction, being from 2 to 6, and at least two pairs of concavities each pair of which are mutually oppositely protruded inward from two sides of the flat cross-section facing each other extending along the maximum width B in the flat cross-sectional profile being formed, whereby the polyester pile fabric shows a very soft hand, high abrasion resistance and a bathochromic effect.
For the polyester pile fabric of the present invention, the individual fiber thickness of the flat polyester fibers for the pile portion is preferably from 0.6 to 1.4 dtex.
For the polyester pile fabric of the present invention, the ratio C1/C2 wherein C1 represents the maximum thickness of the flat cross-sectional profile of the flat polyester fibers for the pile portion, and C2 represents the minimum thickness of the profile, is preferably from 1.05 to 4.00.
For the polyester pile fabric of the present invention, the flat polyester filaments for the pile portion preferably comprise a delustering agent in the amount of 2.5% or less by mass or less based on the mass of the flat polyester filaments.
For the polyester pile fabric of the present invention, the flat polyester filament yarns for the pile portion are preferably non-twisted yarns.
For the polyester pile fabric of the present invention, the distribution density of the flat polyester filament piles in the cut pile layer is preferably from 5×10⁴to 20×10⁴dtex/cm², and a pile density cover factor defined by the formula
PDF=PN×1/√D
wherein PDF represents a pile density cover factor, PN represents the number of pile fibers distributed in an area of 1 cm²of the pile layer, and D represents a pile individual filament thickness (dtex), is preferably 2×10⁴or more.
For the polyester pile fabric of the present invention, at least the flat polyester filament yarns from which the pile portion is formed, are preferably dyed yarns.
Fiber articles of the present invention for interior automotive trims or interiors of the present invention comprise any of the polyester pile fabrics mentioned above.
According to the present invention, a polyester pile fabric excellent in soft hand, abrasion resistance and bathochromic effect, and fiber articles for automotive interior trims and home interiors including the polyester pile fabric can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an explanatory cross-sectional profile of the polyester pile fabric of the present invention;
FIG. 2 shows an explanatory cross-sectional profile of an example of flat polyester individual fibers for a pile portion contained in a polyester pile fabric of the present invention;
FIG. 3 shows an explanatory cross-sectional profile another example of the flat polyester individual fibers for a pile portion contained in a polyester pile fabric of the present invention;
FIG. 4 shows an explanatory cross-sectional profile of still another example of the flat polyester individual fibers for a pile portion contained in a polyester pile fabric of the present invention; and
FIG. 5 shows a explanatory perspective view of a contact probe used for testing the hand of the polyester pile fabric of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

In FIG. 1, a polyester pile fabric 1 of the present invention comprises a ground structure portion 2 having a knitted or woven structure that is formed from polyester filament yarns, and a pile portion 3 formed from polyester filament yarns 3 a knitted or woven into the ground structure portion 2. The pile portion 3 is formed on one side of the ground structure portion 2, and has a cut pile layer 3 a formed from the above polyester fibers.
The polyester fibers from which the pile portion 3 and also the cut pile layer 3 a are formed has a individual fiber thickness of 0.5 to 1.5 dtex, preferably 0.6 to 1.4 dtex and a flat cross-sectional shape.
The flat ratio of the cross-sectional profile of a flat polyester individual fiber for the pile portion represented by the ratio B/C1 wherein B represents the maximum width of the cross-sectional profile, and C1 represents the maximum thickness in the direction at right angles to the maximum width B direction, is from 2 to 6, preferably 3 to 5.
In the flat cross-sectional profile, at least two pairs, preferably 3 to 5 pairs of concavities (valley portions), each pair being mutually oppositely extend from opposite two sides of the profile along the maximum width B inward of the flat cross section, are formed.
In a cross section 4 of a polyester individual fiber for a pile portion in FIG. 2, mutually oppositely protruded 3 pairs of concavities (valley portions), namely, a pair 5 a and 5 b, a pair 6 a and 6 b and a pair 7 a and 7 b, are formed from mutually opposite two sides 4 a and 4 b along the maximum length B inward of the cross section 4. In FIG. 2, two pairs of projected portions (mountainous portions) are formed on both sides of each pair of concavities (valley portions). The concavities 5 a and 5 b, the concavities 6 a and 6 b and the concavities 7 a and 7 b each oppositely form a pair of concavities which are substantially symmetric with respect to the centerline 8 in the width direction of the cross section 4. However, each pair of the concavities is not necessarily required to be strictly symmetric. The ratio C1 /C2 wherein C1 represents the maximum width of the cross section, and C2 represents a minimum value of a space between the pair of concavities, is preferably from 1.05 to 4.00, more preferably from 1.10 to 2.50.
A polyester individual fiber having a flat cross-sectional profile, as explained above, is flat. On a pair of opposite flat surfaces on both respective sides of the centerline in the transverse direction of the filament, at least two pairs of grooves, each pair being mutually oppositely protruded toward the inside from the respective flat surfaces, extend along the longitudinal direction of the flat individual fiber.
That is, polyester individual fibers from which the cut pile layer of the pile fabric of the present invention is formed, has a flat cross-sectional profile. On the pair of flat surfaces of the fiber, at least two pairs of grooves, each pair extending along the longitudinal direction of the single filament and being mutually opposed, are formed.
In the cross-sectional profile of the flat polyester individual fibers for the pile portion used in the present invention, when the number of pairs of constrictions, each formed by a pair of mutually opposite two concavity portions, is one or more, the friction coefficient of the peripheral surface of the flat polyester individual fibers from which the cut piles are formed, increases and the abrasion resistance becomes insufficient. Moreover, when the ratio B/C1 of the flat cross-sectional profile of the flat polyester individual fiber is less than 2, the bending stiffness of the individual increases, and a desired soft hand cannot be obtained. Furthermore, when the ratio exceeds 6, the flat form is deformed or divided by the action of an external force such as abrasion, and the appearance quality is impaired.
Furthermore, the ratio C1 /C2 of a flat polyester individual fibers from which the cut piles are formed, is a parameter related to the depth of the concavities (valley portion). When the ratio C1 /C2 is less than 1.02 (that is, when the depth of the concavities is too small), the friction coefficient of the flat polyester individual fibers thus obtained increases, and the abrasion resistance becomes inadequate. Moreover, when the ratio C1 /C2 exceeds 4.00 (that is, when the depth of the concavities becomes too large), the improvement effect of the abrasion resistance created by concavities is saturated, and the spinning step is destabilized. As a result, cracks are formed in the individual fiber along the concavity portion, or uniformity of the shape and performance of the individual fiber is lowered.
In the flat cross-sectional profile of an individual fiber shown in FIG. 3, the depths of concavities (valley) portions 5 a, 5 b, 6 a, 6 b, 7 a and 7 b are relatively shallow, and two pairs of mountainous portions, each pair being on both respective sides of a pair of concavity (valley) portions, form relatively gentle curves. Flat polyester fibers having such a cross-sectional profile are characterized in that they are soft and highly lustrous.
In the flat cross-sectional profile of an individual fiber shown in FIG. 4, three pairs of concavity (valley portions) and two pairs of mountain portions on both respective sides of each pair of the concavities are formed. The width and height of the mountain portion between the concavities 6 a and 7 a and those of the mountain portion between the concavities 6 b and 7 b are smaller than those of the other mountain portions.
The flat polyester individual fibers for a pile portion used in the present invention has an individual fiber thickness of 0.5 to 1.5 dtex, preferably 0.6 to 1.4 dtex. When the individual fiber thickness exceeds 1.5 dtex, the flexibility of the cut pile layer thus obtained becomes insufficient. Moreover, when the individual fiber thickness is less than 0.5 dtex, the cut pile layer thus obtained has an adequate soft hand. However, the mechanical strength of the cut pile fibers becomes insufficient, and the abrasion resistance of the cut pile layer becomes inadequate.
The flat polyester fibers for a pile portion used for the pile fabric of the present invention preferably contains a delustering agent in an amount of 2.5 mass % or less, more preferably 0 to 1.5 mass % based on the fiber mass. When the content of a delustering agent exceeds 2.5 mass %, the flat polyester filaments thus obtained sometimes show an insufficient bathochromic effect. The delustering agent used for the flat polyester filaments of the present invention can be selected from conventional delustering agents for polyester filaments. However, use of a delustering agent having a high refractive index (e.g., TiO₂, SiO₂and BaSO₄) and having an average particle size of about 0.1 to 1 μm is preferred, and use of a delustering agent containing TiO₂is more preferred.
The polyester filaments yarns for a cut pile layer used in the present invention are preferably non-twisted yarns. When the yarns are twisted, the bending stiffness of individual filaments increases, and a desired soft hand sometimes cannot be obtained. Moreover, the polyester fiber for the cut pile layer may be crimped, or may not be crimped. The polyester filaments can be crimped by a conventional procedure such as false twisting, air-jet crimping and compression crimping. In addition, when the polyester filaments are crimped, the percentage of crimp is preferably 1% or more (more preferably from 1 to 10%).
Although there is no specific restriction on the height of the polyester fiber piles of the cut pile layer, the pile height is preferably from 0.5 to 1.5 mm. When the pile height is less than 0.5 mm, a soft hand might be impaired. Moreover, when the pile height exceeds 1.5 mm, the pile fibers are sometimes laid flat to lower the soft hand of the cut pile layer.
Furthermore, the distribution density of the above polyester fiber piles in the cut pile layer is preferably from 5×10⁴to 20×10⁴dtex/cm², more preferably from 6×10⁴to 12×10⁴dtex/cm², and the pile density cover factor is preferably 2×10⁴or more (more preferably from 6×10⁴to 2.5×10⁵). The pile density and the pile density cover factor influence the bathochromic effect. A higher pile density improves the bathochromic effect. However, when the pile density exceeds 1.2×10⁵dtex/cm², the soft hand might be impaired. Moreover, when the pile density cover factor is less than 2×10⁴, the pile fibers might be laid flat.
In addition, the pile density may be calculated by counting a number of individual fibers per cm², and multiplying the number by the thickness of the individual fibers. However, for example, when the pile fabric of the present invention is a warp knitted fabric, the pile density may be calculated by the following equation: pile density=number of courses per cm×number of wales per cm×total thickness (dtex) of yarns for the pile 2, wherein the total thickness is the product of the individual fiber thickness (dtex) of the yarn for the piles and the number of individual fibers per yarn. Moreover, the pile density cover factor may be obtained by directly counting the number of individual fibers per cm², and multiplying the number by the inverse of the root of the individual fiber thickness. However, for example, when the pile fabric of the present invention is a warp knitted fabric, the pile density cover factor may be calculated by the following equation: Pile density cover factor=number of courses per cm×number of wales per cm×the inverse of the root of the individual fiber thickness (dtex) of the yarn for the piles×the number of individual fiber per yarn×2, wherein the total thickness is the product of the individual fiber thickness (dtex) of the yarn for piles and the number of individual fibers per yarn.
That is, the pile density cover factor can be calculated by the following equation:
PDF=PN×1/√D
wherein PDF represents the pile density cover factor, PN represents the number of pile fibers distributed in an area of 1 cm²of the pile layer, and D represents a thickness (dtex) of a pile individual fibers.
In the present invention, a conventional polyester produced from a dicarboxylic acid component and a diglycol component can be used as a polyester resin for forming the flat polyester filaments for a pile portion.
It is preferred that terephthalic acid be mainly used as the dicarboxylic acid component. Moreover, it is preferred that at least one alkylene glycol selected from ethylene glycol, trimethylene glycol and tetramethylene glycol be mainly used as the diglycol component. Moreover, the polyester resin may be made to contain a third component in addition to the above dicarboxylic acid component and glycol component. Examples of the third component include a cationic dye-dyeable anionic component such as sodiosulfoisophthalic acid, dicarboxylic acids other than terephthalic acid, for example, isophthalic acid, naphthalenedicarboxylic acid, adipic acid, and sebacic acid and glycol compounds other than alkylene glycols such as diethylene glycol, poly(ethylene glycol), bisphenol A and bisphenolsulfone. At least one of these compounds may be used. Furthermore, at least one of the following materials may be optionally contained in addition to the above delustering agents: micropore-forming agents (organic sulfonic acid metal salts), anti-coloring agents, thermal stabilizers, flame retardants (diantimony trioxide), fluorescent brighteners, coloring pigments, antistatic agents (sulfonic acid metal salts), hygroscopic agents (polyoxyalkylene glycols), antibacterial agents and other inorganic particles.
In addition, the cut pile layer of the pile fabric of the present invention is preferably formed out of the polyester cut pile fibers alone. However, the cut pile layer may be made to contain other cut pile fibers as long as the amount is less than 30 wt %.
The ground structure portion of the pile fabric of the present invention has a knitted or woven structure formed out of a polyester filaments yarn. The above-mentioned polyester resins may be used for forming the polyester filaments for the ground structure. The content of a delustering agent is not specifically limited. Moreover, in view of not impairing the hand of the fabric, individual fiber thickness and total size of the polyester filaments yarn for the ground structure are preferably from 0.5 to 5.0 dtex and from 30 to 300 dtex, respectively. Furthermore, there is no specific restriction on the cross-sectional profile of the individual fibers. The cross-sectional profile may be triangular, flat, flat and necked, cross, hexagonal or hollow in addition to being round. Still furthermore, the polyester filament yarn may be false twisted yarn or a composite yarn in which at least two constituent yarns are air-jet combined or composite false twisted, or it may be a covered yarn in which an elastic yarn is placed in the core portion and an inelastic yarn is placed in the sheath portion.
There is no specific limitation on the knitted or woven structure of the pile fabric in the present invention. Examples of the structure include a pile fabric obtained by cutting a loop pile of a fabric such as a warp pile woven fabric, a weft pile woven fabric, a sinker pile knitted fabric, a raschel pile knitted fabric or a tricot pile knitted fabric, and a pile fabric obtained by center-cutting a pile woven fabric prepared with a moquette (double weave) weaving machine.
The pile fabric of the present invention can be produced by, for example, the following production process.
First, polyester filament yarns for pile portion having a flat cross section with at least 2 necked portions and a cross-sectional flat ratio of 2 to 6, and an individual fiber thickness of 1.5 dtex or less is produced by, for example, spinning a polyester resin through a spinneret having injection nozzles as shown in FIG. 2 C on page 5 in Japanese Unexamined Patent Publication (Kokai) No. 56-107044. On the other hand, a polyester filament yarns for the ground structure portion is produced by spinning a polyester resin using a conventional spinneret. A pile fabric is produced from both yarns.
The pile portion having a knitted fabric structure is formed during the production by the following procedure. The ground structure is knitted, and a loop pile structure extending thereabove such as a sinker pile, a pole tricot pile or a double raschel pile is formed, followed by forming a cut pile layer by cutting the loop pile. The pole tricot pile is obtained by forming the pile knitted portion of a tricot knitted structure into a loop pile with a raising machine.
On the other hand, the pile portion having a woven fabric structure is formed by the following procedure. A warp pile or weft pile woven fabric is woven, and the loop pile is cut to form a cut pile layer; or a moquette woven fabric is woven, and the pile yarn is center cut to form a cut pile layer.
The pile fabric of the present invention is usually preset by a dry heat treatment, and then conventionally dried and final dry heat treated. The preset dry heat treatment temperature is preferably from 150 to 200° C., and the dyeing temperature is preferably from 130 to 135° C. The final dry heat treatment temperature is preferably from 140 to 160° C.
In addition, another known layer such as a back coating layer or a pile layer may be formed on the side opposite to the cut pile layer in the ground structure portion of the pile fabric of the present invention. Moreover, the opposite side may be subjected to patterning by conventional etching, embossing, alkali reduction, color printing, water repellent finishing, and other various processes for imparting agents such as a UV shielding agent, an antibacterial agent, a deodorant, a mothproofing agent, a luminous agent, a retroreflecting agent and a negative ion-generating agent.
The polyester fibers of the cut pile layer in the pile fabric of the present invention thus obtained have a flat cross section, and the individual fiber thickness is as small as 1.5 dtex or less. As a result, the bending stiffness is low, and a good soft hand is obtained. Moreover, because constrictions are formed in the flat cross sectional profile, the contact area formed when another material is contacted with the cut pile layer is decreased. As a result, the friction resistance is small, and an excellent abrasion resistance is obtained. At the same time, the roughening effect of the constrictions produces the effect of giving a high bathochromic effect.

EXAMPLES

The present invention is explained in detail by making reference to the following examples. However, the present invention is in no way restricted thereto. In addition, physical properties in the examples were determined by the following methods.
(1) Hand
A surface property tester (trademark: KES F4, manufactured by Kato Tech Co., Ltd.) was used. A fabric to be tested is cut to give a test peace, 20 cm×20 cm. The test peace was pressed with the bottom face of a contact probe having been prepared by bending 10 piano wire pieces each having a diameter of 0.5 mm under a load of 98 mN (10 gf). The surface friction coefficient p of the test peace in the warp direction and that in the weft direction were each determined at a moving speed of the test peace of 0.1 cm/sec under a measurement tension of 196 mN (20 gf)/cm. In addition, the number of n was 5, and the average value was obtained.
(2) Abrasion Resistance 1
The abrasion resistance of a specimen of a fabric was evaluated in accordance with JIS L 1096-1990, 6.32 4 D method (Martin Dale method). The specimen was rotated 20,000 times, and the change in color by abrasion is evaluated on a gray scale for a change in color. In addition, the number of n was 5, and the average value was obtained.
(3) Abrasion Resistance 2
The pile fallout by abrasion of a fabric was evaluated in accordance with JIS L 0894 Gakushin tester method. The fabric to be tested was cut to give a test piece, 20 cm×3 cm. The test peace was rotated 10,000 times under a load of 9.8 N (1.0 kgf), and the pile fallout by abrasion of the test peace was evaluated. In addition, the number of n was 5, and the average value was obtained.
(4) Surface Appearance
The laying flat state of pile fibers was visually observed, and evaluated according to the following criteria: Excellent: good without laying flat; Good: usual; and Bad: not good with laying flat.
(5) Bathochromic Effect
Using a Macbeth Color Eye Model M 2020 (manufactured by Kolmorgen Corp. in U.S.A.), an L value of a test fabric was measured. The light source was D65 standard light, and the observation angle was 10°. In addition, the number of n was 5, and the average value was determined.

Example 1

A poly(ethylene terephthalate) resin containing no delustering agent (titanium oxide) was extruded at a spinning temperature of 300° C. through 72 melt spinning nozzles each having a cross-sectional profile corresponding to a filament cross-sectional profile shown in FIG. 2 (each spinning nozzle having 4 circular arc-like projected portions on each of both sides of the longitudinal center line, and 3 concavity portions formed between the adjacent circular arc-like projected portions). The extruded yarn was drawn by a conventional method to give a drawn multifilaments yarn having a yarn count of 88 dtex/72 filaments (individual fiber thickness of 1.2 dtex) for yarns for pile yarns. The yarn for a pile yarn was composed of filaments (individual filaments) each having a cross-sectional profile as shown in FIG. 2. The cross-sectional flat ratio (B/C1) of the cross-sectional profile was 3.2. In the flat cross section, the ratio (C1 /C2) of a maximum value (C1) of the width to a minimum value (C2) thereof was 1.2.
On the other hand, a drawn multifilaments yarn having a yarn count of 84 dtex/36 filaments were prepared by extruding a conventional poly(ethylene terephthalate) resin through melt spinning nozzles having a regular round cross sectional profile to spin a yarn and drawing the spun yarn. A drawn yarn usable as a middle yarn for pile fabric was obtained. Moreover, a false twisted multifilaments yarn having a yarn count of 84 dtex/36 filaments was prepared by extruding a conventional poly(ethylene terephthalate) resin through melt spinning nozzles having a regular round cross-sectional profile to spin a yarn, drawing the spun yarn, and conventionally false twisting and crimping the drawn yarn. The resultant yarn was usable as a ground yarn for pile fabric.
Next, using a tricot warp knitting machine manufactured by Karl Meyer, a knitted fabric having a course density of 86 courses/2.54 cm and a wale density of 28 wales/2.54 cm was formed with a swing indication of the bar for the pile yarn of 1034, a swing indication of the bar for the middle yarn of 1023 and a swing indication of the bar for the ground yarn of 1012. The loop pile fabric thus obtained was supplied to a dyeing step, and dyed at 130° C. for 45 minutes with a fluid-stream dyeing machine (manufactured by Hisaka Works, Ltd.) with the following dye composition.

- (Dyeing bath):
- Teratop Blue HLB (trade name, manufactured by Ciba Geigy) 0.4% (based on the fabric mass)
- Irgasol Dam (trade name, manufactured by Ciba Geigy)
- 1 g/liter
- Acetic acid 0.5 g/liter
  After dyeing, the resultant dried fabric was placed in a short loop drier (manufactured by Hirano Tecseed Co., Ltd.), to dry it. The dried fabric was subjected to raising agent treatment using a padding machine (manufactured by Hirano Tecseed Co., Ltd.), and supplied to a drying setter where the fabric was preset by a dry heat treatment at 170° C. for 1 minute while the fabric was held in a open-width state. The tip portions of the loop piles were then raised and cut with a card clothing raising machine (manufactured by Nikki Co., Ltd.). The tip portions of the loop piles were then sheared with a shearing machine (manufactured by Nikki Co., Ltd.) to form cut piles (pile height of 1 mm). The cut piles thus obtained were subjected to final dry heat treatment at 160° C. for 1 minute with a drying setter (manufactured by Hirano Tecseed Co., Ltd.) to give a pile fabric having a course density of 79 curses/2.54 cm and a wale density of 43 wales/2.54 cm.

The pile fabric thus obtained had the following properties: a pile density of 9.27×10⁴dtex/cm²; a pile density cover factor of 6.86×10⁴; an individual fiber thickness of the polyester cut pile fibers of 1.2 dtex; a bathochromic effect in terms of L value of 4.92; an abrasion resistance 1 (by Martin Dale method) of class 3 to 4; an abrasion resistance 2 (Gakushin tester method) of class 3; a surface friction coefficient μ in the warp direction of 0.32; a surface friction coefficient μ in the weft direction of 0.297; and an excellent surface appearance. The fabric therefore had a high soft hand, a high abrasion resistance and a significant bathochromic effect.

Comparative Example 1

A pile fabric was produced in the same manner as in Example 1 with exceptions as explained below. The yarn for a pile yarn was produced by extruding a conventional poly(ethylene terephthalate) resin through a regular round cross-sectional melt spinning nozzles to spin a yarn, and drawing the spun yarn. The resultant drawn multifilaments yarn had a yarn count of 56 dtex/144 filaments. A knitted fabric having a course density of 90 courses/2.54 cm and a wale density of 28 wales/2.54 cm was formed out of the drawn multifilament yarn. The pile fabric obtained from the knitted fabric had a course density of 79 courses/2.54 cm and a wale density of 43 wales/2.54 cm.
The pile fabric thus obtained had the following properties: a pile density of 5.61×10⁴dtex/cm²; a pile density cover factor of 2.31×10⁵; an individual fiber thickness of the polyester cut pile fibers of 0.39 dtex; a bathochromic effect in terms of L value of 6.64; an abrasion resistance 1 (by Martin Dale method) of class 3; an abrasion resistance 2 (Gakushin tester method) of class 2; a surface friction coefficient μ in the warp direction of 0.313; a surface friction coefficient μ in the weft direction of 0.325; and an excellent surface appearance. The fabric therefore had a poor abrasion resistance and a poor color deepening effect.

Comparative Example 2

A pile fabric was produced in the same manner as in Example 1 with the exceptions explained below. The yarn for a pile yarn was produced by extruding a conventional poly(ethylene terephthalate) resin through a regular flat cross-sectional melt spinning nozzles to a yarn, and drawing the spun yarn. The drawn multifilaments yarn was a flat filament yarn having no constrictions, and had a yarn count of 88 dtex/72 filaments. A knitted fabric having a course density of 90 courses/2.54 cm and a wale density of 28 wales/2.54 cm was formed out of the drawn multifilaments yarn. The pile fabric obtained from the knitted fabric had a course density of 79 courses/2.54 cm and a wale density of 43 wales/2.54 cm.
The pile fabric thus obtained had the following properties: a pile density of 9.26×10⁴dtex/cm²; a pile density cover factor of 6.86×10⁴; an individual fiber thickness of the polyester cut pile fibers of 1.2 dtex; a bathochromic effect in terms of L value of 5.64; an abrasion resistance 1 (Martin Dale method) of class 3; an abrasion resistance 2 (Gakushin tester method) of class 2; a surface friction coefficient μ in the warp direction of 0.313; a surface friction coefficient μ in the weft direction of 0.325; and an excellent surface appearance. The fabric therefore had a poor abrasion resistance and a poor bathochromic effect.

INDUSTRIAL APPLICABILITY

The pile fabric of the present invention has a satisfactory soft hand, high abrasion resistance and bathochromic effect, and thus can be used for automotive interior trims such as car sheets and ceiling members, home and office interiors such as upholsteries and carpets, exhibition hall interiors and fiber articles such as clothing. Accordingly, the industrial value of the pile fabric is extremely great.

Claims

1. A polyester pile fabric

comprising a ground structure portion having a knitted or woven structure formed from polyester filaments yarns, and a pile portion comprising a polyester filament yams knitted or woven into the ground structure portion,

the pile portion having a cut pile layer formed on one side of the ground structure portion and comprising the polyester fibers,

the polyester fibers, form which the pile portion is formed, having an individual fiber thickness of 0.5 to 1.5 dtex and a flat cross-sectional profile,

the flat ratio of the flat cross-sectional profile represented by a ratio B/C1 wherein B represents the maximum width of the cross-sectional profile, and C1 represents the maximum thickness the profile in the direction at right angles to the maximum width direction, being from 2 to 6, and at least two pairs of concavities each pair of which are mutually oppositely protruded inward from the two sides of the flat cross section facing each other extending along the maximum width B in the flat cross-sectional profile being formed, whereby the polyester pile fabric exhibits high soft hand, abrasion resistance and bathochromic effect.

2. The polyester pile fabric according to claim 1, wherein the individual fiber thickness of the flat polyester fibers for the pile portion is from 0.6 to 1.4 dtex.

3. The polyester pile fabric according to claim 1, wherein the ratio C1 /C2 wherein C1 represents the maximum thickness in the flat cross-sectional profile of the flat polyester fibers for the pile portion, and C2 is the minimum thickness in the profile, is from 1.05 to 4.00.

4. The polyester pile fabric according to claim 1, wherein the flat polyester filaments for the pile portion contain a delustering agent in an amount of 2.5% or less by mass based on the mass of the flat polyester filaments.

5. The polyester pile fabric according to claim 1, wherein the flat polyester filament yarns for the pile portion are non-twisted yarns.

6. The polyester pile fabric according to claim 1, wherein the distribution density of the flat polyester fiber piles in the cut pile layer is from 5×10⁴to 20×10⁴dtex/cm², and a pile density cover factor defined by the formula;

PDF=PN×1/√D

wherein PDF represents a pile density cover factor, PN represents the number of pile fibers distributed in an area of 1 cm²of the pile layer, and D represents a pile individual filament thickness (dtex), is 2×10⁴or more.

7. The polyester pile fabric according to claim 1, wherein at least the flat polyester filament yams from which the pile portion is are dyed yams.

8. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 1.

9. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 2.

10. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 3.

11. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 4.

12. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 5.

13. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 6.

14. Fiber articles for interior automotive trims or interiors comprising the polyester pile fabric according to claim 7.