Pile fabric, support member, and method for manufacturing the same

Abstract

A pile fabric, a support member, and a manufacturing method thereof, which realize a "new appearance of pile" and the like by forming a pile yarn into a substantially rectangular shape or the like. The present invention is a pile fabric in which a pile yarn is vertically provided from a base fabric. The base fabric has warp yarns and weft yarns, and the pile yarn is caught to one or more weft yarns, and the pile yarn is in a substantially rectangular shape or the like. In addition, the pile yarn is a monofilament yarn, and the warp yarns are arranged in multiple numbers between adjacent pile yarns, and the pile yarn can be caught to three or more weft yarns. The manufacturing method of the pile fabric forms the pile yarn into a substantially rectangular shape or the like by performing a heat treatment process on a top base fabric or a back base fabric that is connected by a connecting yarn after a weaving process in which the base fabric and the pile yarn are woven. In addition, a dissolving process in which a soluble fiber in the weft yarn is dissolved can be provided. Furthermore, the present invention is a support member having the above-described pile fabric and an elastic member, and a manufacturing method of the support member.

Description

Technical Field

[0001] The present invention relates to a pile fabric having a base fabric having warp and weft yarns and pile yarns erected vertically from the base fabric, a support member, and a method for manufacturing the same. Background Technology

[0002] Currently, there is a known terry loop retainer that comprises a base and a terry loop, wherein the terry loop is disposed on the base in a state where its base is combined with the base (Patent Document 1).

[0003] In this terry loop holder, the terry loop forming yarn is approximately cylindrical in shape and is composed of non-absorbent filaments of 0.05 to 0.8 denier arranged radially and closely in the axial direction around the axis of the terry loop forming yarn. The approximately cylindrical outer circumferential surface is formed by the front end of the filaments. The ratio of (height of terry loop) to (diameter of terry loop forming yarn) of the terry loop is 1 / 1 to 5 / 1, and the ratio of (distance between the centers of the two bases of the terry loop) to (diameter of terry loop forming yarn) is 3 / 1 or less. It has self-supporting properties relative to the surface of the substrate.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2010-18892 Summary of the Invention

[0007] The technical problem that the invention aims to solve

[0008] However, the loop pile retainer described in Patent Document 1 is as follows: Figure 1 As disclosed, the shape (appearance) of the terry loop in the side view can also be described as roughly round, requiring a new appearance.

[0009] In view of this, the present invention aims to provide a pile fabric, a support component, and a method for manufacturing the same, which can achieve a "new appearance of the pile" by forming the pile yarn into a generally rectangular shape, etc.

[0010] Technical solutions for solving the problem

[0011] The first feature of the pile fabric 1 of the present invention is that pile yarn 3 is erected from the base fabric 2, the base fabric 2 having warp yarns 4 and weft yarns 5, the pile yarn 3 is secured to one or more weft yarns 5, the front end side of the pile yarn 3 is generally U-shaped when viewed from the side, and / or the base end side is generally upright relative to the base fabric 2 when viewed from the side.

[0012] The second feature of the pile fabric 1 of the present invention is that, based on the first feature mentioned above, the front end of the pile yarn (3) is approximately semi-circular when viewed from the side, and the base end is approximately upright relative to the base fabric (2) when viewed from the side.

[0013] The third feature of the pile fabric 1 of the present invention is that, based on the first or second feature mentioned above, the pile yarn 3 is a monofilament yarn, and the warp yarn 4 is arranged between the pile yarns 3 adjacent to each other in the weft direction, wherein the weft direction is the length direction of the weft yarn 5.

[0014] The fourth feature of the pile fabric 1 of the present invention is that, based on the first to third features described above, the pile yarn 3 is secured to three or more adjacent weft yarns 5 in the warp direction, where the warp direction is the length direction of the warp yarns 4. The pile yarn 3, relative to the three or more adjacent weft yarns 5, passes under one or more of the adjacent three or more weft yarns 5, then passes over another or more of the adjacent three or more weft yarns 5, and then passes under the other or more of the adjacent three or more weft yarns 5 to be secured.

[0015] Based on these features, by forming the front end of the pile yarn 3, which is fixed to one or more weft yarns 5, into a roughly U-shape when viewed from the side, or by forming the base end into a roughly upright shape relative to the base fabric 2 when viewed from the side, the pile yarn 3 becomes roughly rectangular, etc. Therefore, unlike Patent Document 1, where the appearance of the pile yarn when viewed from the side is roughly round, a "new appearance of the pile yarn" can be achieved.

[0016] It should be noted that such pile fabric 1 can also be described as "pile fabric in a roughly rectangular shape, etc."

[0017] Alternatively, the front end of the pile yarn 3 can be formed to be approximately semi-circular when viewed from the side, and the base end can be formed to be approximately upright relative to the base fabric 2 when viewed from the side.

[0018] In addition, by setting the pile yarn 3 as a monofilament yarn and arranging multiple warp yarns 4 between the pile yarns 3 adjacent to each other in the weft direction, the pile yarns 3, which are roughly rectangular or the like, can be set up vertically at a specified interval in the weft direction, thereby achieving a pile with a newer appearance.

[0019] Furthermore, by securing the pile yarn 3 to three or more adjacent weft yarns 5 in the warp direction, it is possible to ensure that the approximate width of the pile yarn 3, which is roughly rectangular or the like, along the warp direction is above a specified value. This allows for the creation of piles with a newer appearance, while also making it more difficult for the roughly rectangular pile yarn 3 to fall off (achieving both a "new appearance of the pile" and "improved prevention of pile falling off" at the same time).

[0020] The present invention relates to a support member for supporting a curable structure. The support member has the aforementioned pile fabric 1 and a plate-shaped elastic element. Its first feature is that the pile fabric 1 is fixed to the outer surface of the elastic element in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic element, and the pile yarn 3 of the pile fabric 1 is embedded in the curable structure.

[0021] Based on this feature, by fixing the pile fabric 1 to the outer surface of the elastic member in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic member, and embedding the pile yarn 3 of the pile fabric 1 into the curable structure, the curable structure such as a roughly rod-shaped concrete is supported by the support member, and the position of the support member and the curable structure is difficult to shift, thereby stabilizing the support ("stabilization of the support").

[0022] The present invention relates to a method for manufacturing a pile fabric 1, which is a method for manufacturing a pile fabric with pile yarns 3 vertically arranged on a base fabric 2. Its first feature is that it comprises: a weaving step S1, in which a front base fabric 2a and a back base fabric 2b having warp yarns 4 and weft yarns 5 are connected by a connecting yarn 3' secured to two or more of the weft yarns 5, and the base fabric 2 and pile yarns 3 are woven together; and 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; the connecting yarns 3' are formed into the pile yarns 3, the front end of the pile yarns 3 being approximately U-shaped in side view, and / or the base end being approximately upright relative to the base fabric 2 in side view.

[0023] The present invention relates to a method for manufacturing a pile fabric 1, which is a method for manufacturing a pile fabric with pile yarns 3 vertically arranged from a base fabric 2. The second feature is that it includes a weaving / heat treatment step S1', in which a front base fabric 2a and a back base fabric 2b having warp yarns 4 and weft yarns 5 are connected by a connecting yarn 3' fixed to two or more of the weft yarns 5, the base fabric 2 and the pile yarns 3 are woven, and the woven front base fabric 2a and / or the woven back base fabric 2b are heat treated to form the connecting yarn 3' into the pile yarns 3. The front end of the pile yarns 3 is generally U-shaped when viewed from the side, and / or the base end is generally upright relative to the base fabric 2 when viewed from the side.

[0024] The third feature of the method for manufacturing the pile fabric 1 of the present invention is that, based on the first or second feature described above, the weft yarn 5 contains soluble fibers and includes a dissolving step S3 for dissolving the soluble fibers.

[0025] Based on these features, after the weaving process S1, a heat treatment process S2 is performed to heat-treat the outer base fabric 2a or the back base fabric 2b, and the connecting yarn 3' between the outer base fabric 2a and the back base fabric 2b is formed into a pile yarn 3 that is approximately U-shaped when viewed from the side at the front end, or approximately upright relative to the base fabric 2 when viewed from the side at the base end, so that the pile yarn 3 becomes approximately rectangular, etc. Therefore, unlike Patent Document 1, which has a roughly round appearance when viewed from the side, a "new appearance of the pile" can be achieved. At the same time, by performing only one weaving process S1 and heat treatment process S2, two pile fabrics 1 with pile yarns 3 that are approximately rectangular, etc., can be manufactured. Therefore, the manufacturing efficiency of the pile fabric 1 is improved (both "new appearance of the pile" and "improved manufacturing efficiency" can be achieved at the same time).

[0026] It should be noted that the manufacturing method of such pile fabric 1 can also be described as "the manufacturing method of pile fabric of roughly rectangular shape".

[0027] In addition, a weaving / heat treatment process S1' can also be provided, which combines the above-mentioned weaving process S1 and heat treatment process S2 into one process.

[0028] Furthermore, by employing a dissolving process S3 that dissolves the soluble fibers contained in the weft yarn 5, the weft yarn 5 containing soluble fibers that is held in place by the connecting yarn 3' is dissolved and released from its hold. Without cutting the connecting yarn 3', which is in the shape of a roughly rectangular pile yarn, the outer base fabric 2a and the back base fabric 2b can be quickly separated, thereby simultaneously achieving both a "new appearance of the pile" and "improved manufacturing efficiency".

[0029] The present invention relates to a method for manufacturing a support component for supporting a curable structure. The support component has a pile fabric 1 manufactured by the above-described manufacturing method and a generally plate-shaped elastic member. Its first feature is that it includes: a fixing step, in which the pile fabric 1 is fixed to the outer surface of the elastic member in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic member; and an embedding step, in which the pile yarn 3 of the pile fabric 1 is embedded in the curable structure.

[0030] Based on this feature, by fixing the pile fabric 1 to the outer surface of the elastic member in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic member, and by embedding the pile yarn 3 of the pile fabric 1 into the curable structure, a curable structure such as a roughly rod-shaped concrete is supported by a support member, and the position of the support member relative to the curable structure is difficult to shift, thereby achieving support stability ("support stabilization").

[0031] Invention Effects

[0032] According to the present invention, the pile fabric, the support component, and the manufacturing method thereof, a "new appearance of the pile" can be achieved by setting the pile yarn to a generally rectangular shape, etc. Attached Figure Description

[0033] Figure 1 The accompanying drawings are photographic representations illustrating the surface perspective of the pile fabrics and the like involved in this invention.

[0034] Figure 2 The accompanying photograph is a substitute photograph illustrating the longitudinal direction of the warp yarns in an example of a pile fabric, etc.

[0035] Figure 3 This is a three-dimensional photograph illustrating the process of separating the outer fabric and the back fabric during the manufacturing method of the pile fabric, etc., as described in the present invention, where both the outer fabric and the back fabric are pile fabrics.

[0036] Figure 4 This is a photograph taken as an example in a manufacturing method of pile fabrics, where both the outer fabric and the back fabric are pile fabrics. The photograph shows the warp direction of the pile fabric at the point where the outer fabric and the back fabric are separated.

[0037] Figure 5 It is a side sectional view showing the weft direction of the pile yarn relative to three or more weft yarns in a pile fabric.

[0038] Figure 6 This is a weave diagram of the back fabric in a pile fabric manufacturing method, where both the outer and back fabrics are pile fabrics, before the outer and back fabrics are separated (the middle weft yarn is one). It should be noted that... Figure 6 The black color in this context refers to the fact that, when viewed from above (from the side of the base fabric), the warp or pile yarn passes over (or above) the weft yarn. Additionally, this... Figure 6 The reference numerals on the weft yarns indicate the reference numerals for the weft yarns in the XX-direction sectional view.

[0039] Figure 7 and Figure 6 This is also a weave diagram of the outer fabric and backing fabric in the pile fabric before the outer and backing fabrics are separated. It should be noted that... Figure 7 The black color in this context also refers to the fact that, when viewed from above (from the back of the fabric), the warp or pile yarn passes over (or above) the weft yarn. Additionally, this... Figure 7 The reference numerals on the weft yarns also indicate the reference numerals for the weft yarns in the XX-direction sectional view.

[0040] Figure 8 yes Figure 6 , Figure 7 The diagram illustrates a cross-sectional view of a pile fabric along the XX direction. Figure 8 (a) indicates the pile fabric before the top base fabric is separated from the back base fabric. Figure 8 (b) indicates the pile fabric after the top base fabric and back base fabric are separated following the dissolving process.

[0041] Figure 9 yes Figure 6 , Figure 7 The diagram illustrates a YY-direction sectional view of a pile fabric. Figure 9 (a) indicates the pile fabric before the top base fabric is separated from the back base fabric. Figure 9 (b) indicates the pile fabric after the top base fabric and back base fabric are separated following the dissolving process.

[0042] Figure 10 yes Figure 6 , Figure 7 The ZZ-direction sectional view of the pile fabric illustrated in the weave diagram. Figure 10 (a) indicates the pile fabric before the top base fabric is separated from the back base fabric. Figure 10 (b) indicates the pile fabric after the top base fabric and back base fabric are separated following the dissolving process.

[0043] Figure 11 yes Figure 6 , Figure 7 The diagram illustrates a VV-direction sectional view of a pile fabric. Figure 11 (a) indicates the pile fabric before the top base fabric is separated from the back base fabric. Figure 11 (b) indicates the pile fabric after the top base fabric and back base fabric are separated following the dissolving process.

[0044] Figure 12 yes Figure 6 , Figure 7 The diagram illustrates a cross-sectional view of a pile fabric along the WW direction. Figure 12 (a) indicates the pile fabric before the top base fabric is separated from the back base fabric. Figure 12 (b) indicates the pile fabric after the top base fabric and back base fabric are separated following the dissolving process.

[0045] Figure 13 This is a flowchart illustrating a method for manufacturing the pile fabric, etc., according to the present invention. Figure 13 (a) represents the first embodiment. Figure 13 (b) indicates the second embodiment. Figure 13 (c) indicates the third implementation method. Figure 13 Example (d) shows a variation.

[0046] Explanation of reference numerals in the attached figures

[0047] 1…pile fabric; 2…base fabric; 2a…outer base fabric; 2b…back base fabric; 3…pile yarn; 3'…connecting yarn; 4…warp yarn; 5…weft yarn; S1…weaving process; S1'…weaving / heat treatment process; S2…heat treatment process; S3…melting process. Detailed Implementation

[0048] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0049] <Overall Composition of Pile Fabric 1>

[0050] Figures 1 to 12 The illustration shows a pile fabric 1 according to an embodiment of the present invention.

[0051] The pile fabric 1 is a fabric having a base fabric 2 (described later) and a plurality of pile yarns 3 woven into the base fabric 2, or the pile yarns 3 are arranged vertically from the base fabric 2.

[0052] The pile fabric 1 can also be first woven into two pile fabrics that are woven into upper and lower layers respectively, and the pile yarn 3 connecting them is cut in the center by the line (called the center cutting line) at approximately the center of the upper and lower pile fabrics 1 to divide them into two pile fabrics 1.

[0053] The thickness of the pile fabric 1 is the sum of the thickness of the base fabric 2 and the upper and lower lengths (pile length) of the pile yarn 3. There is no particular limitation. For example, it can be 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.

[0054] <Kib2>

[0055] like Figures 1 to 12 As shown, the base fabric 2 has warp yarns 4 (described later) and weft yarns 5 (one-sided weft yarn 5a or the other-end weft yarn 5b, and the middle weft yarn 5m) and is constructed by weaving these warp yarns 4 and weft yarns 5.

[0056] There are no particular restrictions on the structure (fabric structure) of the base fabric 2. For example, the warp yarns 4 can be arranged along the width of the fabric, and each warp yarn 4 can also pass under the multiple weft yarns 5 as it passes over them (which can also be called a twill fabric structure).

[0057] In addition, each warp yarn 4 can also pass under one or more weft yarns 5 while passing over one weft yarn 5, which can be said to form a plain weave or twill weave with each weft yarn 5.

[0058] To explain this situation in detail, each warp yarn 4 can be one of the following: passing above one weft yarn 5 and below one weft yarn 5 (plain weave), passing above one weft yarn 5 and below two weft yarns 5 (twill weave), or passing above one weft yarn 5 and below three weft yarns 5 (twill weave).

[0059] The thickness of the base fabric 2 is not particularly limited. For example, it can be 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).

[0060] Furthermore, the width of the base fabric 2 is not particularly limited; for example, it can be 20 inches or more but less than 100 inches (e.g., 65 inches). Similarly, the number of reeds on the loom used to weave the base fabric 2 and the pile yarn 3 is not particularly limited; for example, it can be 10 pieces / inch or more but less than 90 pieces / inch.

[0061] The following is a description of the warp yarns 4 and weft yarns 5 in the base fabric 2.

[0062] <Warp yarn grade 4>

[0063] like Figures 1 to 12 As shown, the warp yarns 4 are arranged along the weaving direction (unidirectional) of the woven base fabric 2, or along the length direction (bidirectional, also known as the warp direction) of the warp yarns 4 (in other words, arranged along the width direction of the fabric).

[0064] Warp yarn 4 can be either filament yarn (long fiber yarn) or staple fiber yarn (short fiber yarn, spinning). If it is filament yarn, it can be monofilament, multifilament, etc., or it can be unprocessed filament yarn (raw yarn).

[0065] The total fineness of the warp yarn 4 is not particularly limited; for example, it can be 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 / 30 filament, 50d / 20 filament, etc.). Furthermore, the fineness of the individual fibers of the warp yarn 4 is not particularly limited; for example, it can be 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.

[0066] The warp yarn 4 can also be arranged between adjacent pile yarns 3 in the weft direction (the weft direction that is the length direction of the weft yarn 5). Between adjacent pile yarns 3, the warp yarn 4 can also be arranged with multiple yarns twisted together.

[0067] The material of warp yarn 4 is also not particularly limited. For example, it can be polyester fiber such as PET, cotton fiber, rayon fiber, nylon fiber, acetate fiber, their twisted yarn, blended yarn, etc.

[0068] In addition, there is no particular limit to the number of warp threads per inch of warp 4, for example, it can be more than 10 threads and less than 30 threads (21 threads, etc.).

[0069] <Weft yarn 5>

[0070] like Figures 1 to 12 As shown, the weft yarn 5 is arranged along the fabric width direction or the length direction 5L (bidirectional, also known as the weft direction) of the woven base fabric 2 (in other words, arranged along the weaving direction).

[0071] Weft yarn 5 can also be a long filament yarn (long fiber yarn) that forms wrinkles and / or undulations. In this case, weft yarn 5 can also be said to be a wool-like processed yarn, and its composition can also be monofilament or multifilament, etc.

[0072] In this invention, "wrinkling" refers to the portion of the weft yarn 5 that is curled up (such as a spiral curled portion), also known as curling.

[0073] In addition, the “undulation” in this invention refers to the curved portion in the weft yarn 5.

[0074] It should be noted that when the warp yarn 4 is a filament, wrinkles or undulations may also be formed on the warp yarn 4, or wrinkles or undulations may not be formed on the warp yarn 4 (the warp yarn 4 may also be an unprocessed filament (raw yarn)).

[0075] Besides the weft yarn 5, it can also be short fiber yarn (short fiber yarn, spinning).

[0076] The total fineness of the weft yarn 5 is not particularly limited. For example, it can be 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 filament, 50d / 30 filament, etc.). Alternatively, it can be a double yarn (20 / 2) formed by twisting two single cotton yarns with a count of 20 together. In addition, the fineness of the individual fibers of the weft yarn 5 is not particularly limited. For example, it can be 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.

[0077] The material of weft yarn 5 is also not particularly limited. For example, it can be polyester fiber such as PET, cotton fiber, rayon fiber, nylon fiber, acetate fiber, their twisted yarn, blended yarn, etc.

[0078] In addition, there is no particular limitation on the number of weft yarns 5 driven in (the number of weft yarns 5 driven in 1 inch in the weaving direction). For example, it can be more than 20 and less than 250, preferably more than 30 and less than 200, and more preferably more than 40 and less than 150 (130), etc.

[0079] The pile yarn 3 described later is locked relative to the weft yarn 5. There is no particular limitation on the number of weft yarns 5 locked relative to the pile yarn 3. For example, each pile yarn 3 may be locked relative to one or more weft yarns 5, or relative to three or more adjacent weft yarns 5.

[0080] The following describes various weft yarns 5 when the pile yarn 3 is locked relative to three or more adjacent weft yarns 5.

[0081] <Various weft yarns 5 that are stuck at a certain time, relative to three or more weft yarns 5>

[0082] like Figures 1 to 12 (in particular Figure 5 As shown, the weft yarn 5 can be arbitrarily configured as long as it is woven with the warp yarn 4 to form the base fabric 2. For example, it can have a weft yarn 5a on one side or a weft yarn 5b on the other side, and an intermediate weft yarn 5m located between these weft yarns 5a on one side and the weft yarn 5b on the other side. These weft yarns 5a, 5b, and 5m can also be arranged along the weaving direction.

[0083] Here, one side weft yarn 5a is the weft yarn 5 located on the far side among three or more adjacent weft yarns 5 in the length direction 4L of the warp yarn 4 and woven into the lower or upper side of the warp yarn 4. The other side weft yarn 5b is the weft yarn 5 located on the far side among three or more adjacent weft yarns 5 in the length direction 4L of the warp yarn 4 and woven into the upper or lower side of the warp yarn 4. The middle weft yarn 5m is the weft yarn 5 other than the aforementioned one side weft yarn 5a and the other side weft yarn 5b among three or more adjacent weft yarns 5 in the length direction 4L of the warp yarn 4 (the weft yarn 5 between one side weft yarn 5a and the other side weft yarn 5b).

[0084] The fineness (total fineness) of the weft yarn 5a on one side or the weft yarn 5b on the other side and the middle weft yarn 5m can all be approximately the same, or conversely, at least two of them can be different. In addition, the materials of the weft yarn 5a on one side or the weft yarn 5b on the other side and the middle weft yarn 5m can also be the same, or conversely, at least two of them can be different.

[0085] Furthermore, for each of the weft yarns 5a, 5b, and 5m, multiple pile yarns 3 are secured along the length direction 4L of the warp yarns 4 to one or more (or zero) adjacent weft yarns 5. Alternatively, for a certain pile yarn 3, it can also be (and concurrently serve as) a weft yarn 5 on one side of the weft yarn 5a, and for other pile yarns 3, it can also be (and concurrently serve as) a weft yarn 5b on the other side or a middle weft yarn 5m.

[0086] It should be noted that, regarding the number of weft yarns 5a, 5b, and 5m, relative to the single pile yarn 3 mentioned later, one weft yarn 5a on one side or one weft yarn 5b on the other side can be said to be one, but the middle weft yarn 5m can also be one or more (one, two, three, etc.).

[0087] Therefore, the number of weft yarns 5 (one side weft yarn 5a or the other side weft yarn 5b, and the middle weft yarn 5m) that are adjacent to each pile yarn 3 in the weaving direction can also be said to be two or more. In particular, if there are two weft yarns 5 that are adjacent to each pile yarn 3 in the weaving direction, then one side weft yarn 5a and the other side weft yarn 5b are one each, and the middle weft yarn 5m is 0. If there are three or more weft yarns 5 that are front and back in the weaving direction that are attached to each pile yarn 3, then one side weft yarn 5a and the other side weft yarn 5b are one each, and the middle weft yarn 5m is one or more.

[0088] <Pile yarn 3>

[0089] like Figures 1 to 12 As shown, multiple strands of pile yarn 3 are woven into the base fabric 2.

[0090] The pile yarn 3 can be arbitrarily configured as long as it is woven into the base fabric 2. For example, it can be sandwiched between a certain warp yarn 4 and other warp yarns 4, and multiple yarns can be arranged along the weaving direction.

[0091] The pile yarn 3 can be either filament yarn (long fiber yarn) or staple fiber yarn (short fiber yarn, spinning). If it is filament yarn, it can be monofilament, multifilament, etc., or it can be unprocessed filament yarn (raw yarn).

[0092] The following description assumes that the pile yarn 3 is a monofilament yarn.

[0093] The fineness (total fineness) of the pile yarn 3 is not particularly limited; for example, it can be 20d (denier) or more and 3000d or less, preferably 50d or more and 1000d or less, and more preferably 100d or more and 600d or less. Furthermore, the fineness of the individual fibers of the pile yarn 3 is not particularly limited; for example, it can be 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.

[0094] The material of the pile yarn 3 is also not particularly limited. For example, it can be polyester fiber such as PET, cotton fiber, rayon fiber, nylon fiber, acetate fiber, their twisted yarn, blended yarn, etc. In addition, it can also be a material made by combining or spinning non-thermoplastic fibers such as cotton fiber or rayon fiber with thermoplastic fibers such as polyester fiber or nylon fiber, acetate fiber, etc.

[0095] In addition, there is no particular limit to the number of yarns per inch of the pile yarn 3; for example, it can be more than 10 and less than 100.

[0096] The front end (pile front end 3a) of such pile yarn 3 is roughly U-shaped when viewed from the side, and / or its base end (pile base end 3b) is roughly upright relative to the base fabric 2 when viewed from the side.

[0097] It should be noted that the pile yarn 3 is a terry loop pile. Therefore, in a terry loop pile (a terry loop portion of the pile yarn 3), there are two portions (vertical portions 3A and 3B) extending along the vertical setting direction of the pile yarn 3 on the pile base end 3b side. The angle (vertical setting angle) α formed by the two vertical setting portions 3A and 3B with the base fabric 2 when viewed from the side is approximately 90°, or the vertical setting angle α can 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. In addition, the vertical setting angle α of each of the two vertical setting portions 3A and 3B can be approximately the same or different. Furthermore, each of the two vertical setting portions 3A and 3B may have a circular portion (approximately 1 / 4 circular portion when viewed from the side) between it and the base fabric 2.

[0098] On the other hand, on the front end 3a side of a loop pile portion, there are two portions (vertical setting portions 3A and 3B) extending along the vertical setting direction (up and down direction) of the pile yarn 3, and one portion (connecting portion 3C) extending from the front end side of the vertical setting portions 3A and 3B approximately parallel to the surface of the base fabric 2 (warp direction and front and back direction) and connecting the front and back vertical setting portions 3A and 3B. The angle (connecting angle) β formed by the two vertical setting portions 3A and 3B with the connecting portion 3C when viewed from the side is approximately 90°, or the connecting angle β can 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 the two vertical installation parts 3A and 3B and the connecting part 3C can be approximately the same or different. Furthermore, there can be a circular portion (approximately 1 / 4 circle when viewed from the side) between the two vertical installation parts 3A and 3B and the connecting part 3C.

[0099] In addition, the pile yarn 3 may be approximately semi-circular in side view at the front end 3a side, and approximately upright in side view at the base end 3b side relative to the base fabric 2. In this case, it can also be said that the pile yarn 3 is approximately half-circular in side view at the front end (upper end) of the upright setting part 3A on one side, through the connecting part 3C to the front end (upper end) of the upright setting part 3B on the other side.

[0100] The pile yarns 3 mentioned above can also be secured to one or more weft yarns 5 as described above, or secured to three or more weft yarns 5 adjacent to each other in the warp direction.

[0101] In cases where each pile yarn 3 is secured relative to one or more weft yarns 5, but only one pile yarn 3 is secured, it passes under that single weft yarn 5 and is thus secured. In this case, it can also be said that each pile yarn 3 constitutes a loose pile. Alternatively, in this case, it can also be said that each pile yarn 3 is not secured to the warp yarn 4.

[0102] In cases where each pile yarn 3 is secured relative to one or more weft yarns 5, and the pile yarn 3 is secured only to two adjacent (front and back) weft yarns in the weaving direction, it passes continuously under the two weft yarns 5 and is secured (if it passes under only one of the two weft yarns 5 and is secured, it becomes the case of being secured only to the aforementioned single weft yarn 5). In this case, it can also be said that each pile yarn 3 constitutes a loose weft pile. Furthermore, in this case, it can also be said that each pile yarn 3 is not secured to the warp yarn 4.

[0103] The following describes various weft yarns 5 when the pile yarn 3 is locked relative to three or more adjacent weft yarns 5.

[0104] In addition, each pile yarn 3 can also, as described above, pass under one or more of the three or more adjacent weft yarns 5 (the aforementioned one-sided weft yarn 5a or the other-sided weft yarn 5b, and the middle weft yarn 5m) in the weaving direction, and then pass over another or more of the three or more adjacent weft yarns 5 and then pass under the other or more of the three or more adjacent weft yarns 5 to be locked in place.

[0105] In this case, it can also be said that each pile yarn 3 constitutes a fast pile. Alternatively, in this case, it can also be said that each pile yarn 3 is not secured to the warp yarn 4.

[0106] The details of each pile yarn 3 being secured to three or more weft yarns 5 are as follows: <1-1-1> Each time the pile yarn 3 passes under one of the adjacent three or more weft yarns 5, it passes over another of the adjacent three or more weft yarns 5, and then passes under the other of the adjacent three or more weft yarns 5 to be secured; or, <1-1-2> Each time the pile yarn 3 passes under one of the adjacent three or more weft yarns 5, it passes over the other of the adjacent three or more weft yarns 5 to be secured. The yarn passes over another weft yarn 5 in the group 5, and then is secured below several other weft yarns 5 among the three or more adjacent weft yarns 5. Alternatively, <1-2-1> each time it passes under one of the three or more adjacent weft yarns 5, it passes over several other weft yarns 5 among the three or more adjacent weft yarns 5, and then is secured below another weft yarn 5 among the three or more adjacent weft yarns 5. Alternatively, <1-2-2> each time it passes under one of the three or more adjacent weft yarns 5... At that time, it passes over the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, and then passes under the other multiple multiple weft yarns 5 among the three or more adjacent weft yarns 5 and is locked in place; or, <2-1-1> each time it passes under the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, it passes over the other weft yarn 5 among the three or more adjacent weft yarns 5, and then passes under the other weft yarn 5 among the three or more adjacent weft yarns 5 and is locked in place; or, <2-1-2> each time it passes over the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, it passes over the other weft yarn 5 among the three or more adjacent weft yarns 5 and is locked in place; or, <2-1-2> each time it passes over the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, it passes over the other weft yarn 5 among the three or more adjacent weft yarns 5 and is locked in place. When multiple weft yarns 5 pass under the above-mentioned weft yarns 5, they pass over another weft yarn 5 among the three or more adjacent weft yarns 5, and then pass under the other multiple weft yarns 5 among the three or more adjacent weft yarns 5 and are locked in place. Alternatively, <2-2-1> each time multiple weft yarns 5 pass under the adjacent three or more adjacent weft yarns 5, they pass over the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, and then pass under the other multiple weft yarns 5 among the three or more adjacent weft yarns 5 and are locked in place. Alternatively, <2-2-2> each time multiple weft yarns 5 pass under the adjacent three or more adjacent weft yarns 5, they pass over the other multiple weft yarns 5 among the three or more adjacent weft yarns 5, and then pass under the other multiple weft yarns 5 among the three or more adjacent weft yarns 5 and are locked in place.

[0107] It should be noted that, since each pile yarn 3 is a terry loop pile, each pile yarn 3 does not have a portion (pile piece portion) that protrudes from the base fabric 2 by cutting the pile yarn 3 in the middle. It should also be noted that the terry loop portion of each pile yarn 3 can be described as having a portion extending in the vertical direction (that is, a vertically arranged portion 3A on one side (front side) and a vertically arranged portion 3B on the other side (rear side)) and a portion extending in the warp direction (front-back direction) and connecting the vertically arranged portions 3A and 3B (that is, the connecting portion 3C).

[0108] The vertical length (pile length) of each pile yarn 3 (terry pile portion) is the vertical length of each of the vertically arranged portions 3A and 3B in each terry pile portion, and there is no particular limitation. For example, it can be 0.1mm or more and 30.0mm or less, preferably 0.5mm or more and 20.0mm or less, and more preferably 1.0mm or more and 10.0mm or less (3.5mm or 3.41mm, etc.).

[0109] In addition, the warp length (front and back length) of each pile yarn 3 (terry pile portion) refers to the warp length of the connecting portion 3C in each pile pile portion, and there is no particular limitation. For example, it can be 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 (2.0 mm, etc.).

[0110] From this point onward, the following will describe the relationship between the total number of weft yarns 5, the number of intermediate weft yarns 5m, and the middle part 3M of each pile yarn 3 when each pile yarn 3 is fixed to three or more weft yarns 5.

[0111] With three weft yarns 5 in total, one weft yarn 5a on one side and one weft yarn 5b on the other side are each one, so the number of middle weft yarns 5m is one. Each pile yarn 3, relative to the three adjacent (front and back) weft yarns 5 in the weaving direction (one weft yarn 5a on one side or one weft yarn 5b on the other side and the middle weft yarn 5m respectively), passes under the weft yarn 5a on the farthest side, passes over the middle weft yarn 5m, and then passes under the weft yarn 5b on the farthest side.

[0112] In addition, when there are four weft yarns 5 in total, one weft yarn 5a on one side and one weft yarn 5b on the other side are one each, so there are two middle weft yarns 5m. Each pile yarn 3 can pass under the weft yarn 5a on the farthest side, for example, pass over the two middle weft yarns 5m at the same time, and then pass under the weft yarn 5b on the farthest side, relative to the four weft yarns 5 adjacent in the weaving direction (one weft yarn 5a on one side or one weft yarn 5b on the other side and two middle weft yarns 5m respectively).

[0113] Similarly, when the total number of weft yarns 5 is five, one weft yarn 5a on one side and one weft yarn 5b on the other side are one each, so the number of middle weft yarns 5m is three. Each pile yarn 3, relative to the five weft yarns 5 adjacent in the weaving direction (one weft yarn 5a on one side or one weft yarn 5b on the other side and three middle weft yarns 5m respectively), can also pass under the weft yarn 5a on the far side, for example, by passing over the middle weft yarn 5m each time (passing over the middle weft yarn 5m on the far side of the three middle weft yarns 5m, then passing under the middle weft yarn 5m in the center of the weaving direction, then passing over the middle weft yarn 5m on the far side), and then passing under the weft yarn 5b on the far side.

[0114] Furthermore, when the total number of weft yarns 5 is six, with one weft yarn 5a on one side and one weft yarn 5b on the other side, the number of middle weft yarns 5m is four. Each pile yarn 3, relative to the six weft yarns 5 adjacent in the weaving direction (one weft yarn 5a on one side or one weft yarn 5b on the other side and four middle weft yarns 5m respectively), can also pass under the weft yarn 5a on the far side, for example, by passing over the two middle weft yarns 5m one at a time (passing over the middle weft yarn 5m on the far side of the four middle weft yarns 5m and the middle weft yarn 5m on the side in the center of the weaving direction at the same time, and then passing over the middle weft yarn 5m on the other side of the center of the weaving direction and the middle weft yarn 5m on the far side at the same time), and then pass under the weft yarn 5b on the far side.

[0115] Furthermore, the same applies when the total number of weft yarns 5 is seven or more.

[0116] <Manufacturing method of pile fabric 1, weaving process S1, heat treatment process S2>

[0117] like Figure 3 , Figure 4 , Figures 8 to 13 As shown, the method for manufacturing the pile fabric 1 according to the embodiments of the present invention is the method for manufacturing the pile fabric 1 by weaving the pile yarn 3 into the base fabric 2 as described previously (hereinafter also referred to as "the manufacturing method").

[0118] The manufacturing method includes a weaving process S1 and a heat treatment process S2 (the manufacturing method that only includes a weaving process S1 and a heat treatment process S2 is taken as the first embodiment).

[0119] Furthermore, the manufacturing method may also include a dissolution step S3 (the manufacturing method that includes a dissolution step S3 in addition to the weaving step S1 and the heat treatment step S2 is referred to as the second embodiment).

[0120] The weaving process S1 is a process in which the base fabric 2a and the back base fabric 2b, which have warp yarns 4 and weft yarns 5 respectively, are connected by the connecting yarn 3' fixed to two or more weft yarns 5, and the base fabric 2 and the pile yarn 3 are woven together.

[0121] In addition, the heat treatment process S2 is a process of heat treating the outer base fabric 2a and / or the back base fabric 2b after the above-mentioned weaving process S1.

[0122] This manufacturing method, by including the aforementioned weaving process S1 and heat treatment process S2, forms the connecting yarn 3' into a pile yarn 3 that has a roughly U-shaped front end when viewed from the side and / or a roughly upright shape relative to the base fabric 2 when viewed from the side.

[0123] <Dissolving process S3>

[0124] The weft yarn 5 contains soluble fibers, and the dissolving process S3 is a process that dissolves the soluble fibers.

[0125] In this invention, "the weft yarn 5 contains soluble fibers" means that among multiple weft yarns 5 there is one or more weft yarns that only contain soluble fibers (referred to as soluble weft yarn 5'), or that among multiple weft yarns 5 there is one or more weft yarns 5 that contain at least soluble fibers, etc.

[0126] Hereinafter, the weft yarn 5 containing soluble fibers will be mainly described as a soluble weft yarn 5' containing only soluble fibers.

[0127] It should be noted that the soluble weft yarn 5' and other weft yarns containing soluble fibers can be either filament (long fiber yarn) or staple fiber yarn (short fiber yarn, spinning). If it is filament yarn, it can be monofilament (called soluble monofilament yarn), multifilament (called soluble multifilament yarn), or filament yarn that forms wrinkles or undulations, or it can be filament yarn (raw yarn) that has not undergone any processing.

[0128] In addition, "soluble fiber" in this invention refers to a fiber that can be dissolved, such as a water-soluble fiber that can be dissolved in water (water-soluble vinylon (PVA) fiber, etc.).

[0129] In this case, there is no particular limitation on the temperature of the water at which the water-soluble fiber begins to dissolve. For example, it can be 60℃, or it can be 30℃, 55℃, 70℃, 80℃, 90℃, 95℃, etc.

[0130] Furthermore, the "soluble fiber" in this invention can also be a synthetic fiber that dissolves at a specified temperature (melting point) through heat treatment or the like, such as polyester fiber such as low-melting-point PET, or polyolefin fiber such as low-melting-point PE or low-melting-point PP.

[0131] In this case, there is no particular limitation on the temperature at which the soluble fiber, as a synthetic fiber, begins to dissolve; for example, it can be 96℃~100℃, or it can be 110℃, etc.

[0132] The fineness (total fineness) of the weft yarn 5 containing soluble fibers, such as the soluble weft yarn 5', is not particularly limited. For example, it can be 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. Furthermore, the fineness of the individual fibers of the weft yarn 5 containing soluble fibers is not particularly limited. For example, it can be 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.

[0133] Furthermore, in the case of a weft yarn 5 containing soluble fibers, such as a soluble weft yarn 5', there is no particular limitation on the number of weft yarns 5 containing such soluble fibers per inch, for example, it can be more than one and less than 20.

[0134] The soluble weft yarn 5' and other weft yarns containing soluble fibers described above can also be used on at least a portion of the weft yarn 5 secured by the connecting yarn 3' (pile yarn 3) in at least one of the outer base fabric 2a and the back base fabric 2b.

[0135] When the manufacturing method includes a dissolution step S3, the order of each step in the manufacturing method can be after the heat treatment step S2. Specifically, it can be the order of weaving step S1, heat treatment step S2, and dissolution step S3, or it can be the order of weaving step S1, dissolution step S3, and heat treatment step S2.

[0136] After such a dissolving process S3, only one of the outer base fabric 2a and the back base fabric 2b can be used as pile fabric 1, while the other one does not have pile yarn 3 and is not used as pile fabric 1 (called waste base fabric) (called separation process (separation process of pile fabric 1 and waste base fabric) S4).

[0137] Additionally, after the dissolution process S3, the weft yarns 5 (such as the intermediate weft yarn 5m) adjacent to the dissolved soluble weft yarn 5' in the front and rear (warp direction) directions can also be shifted towards the location where the soluble weft yarn 5' exists (see reference). Figures 8 to 11 (b) etc.), the traces of the looped pile portion in the separated pile yarn 3 being stuck to the soluble weft yarn 5' disappear, and it can also become roughly rectangular, etc. (refer to) Figures 1 to 5 wait).

[0138] Furthermore, after the dissolving process S3, the outer base fabric 2a and the back base fabric 2b can also be separated (this can also be called the separation process (separation process of the pile fabric 1 on the outer base fabric 2a side and the pile fabric 1 on the back base fabric 2b side) S4), and both the outer base fabric 2a and the back base fabric 2b are used as pile fabric 1 (refer to...). Figure 3 , Figure 4 The following is an example of this situation. It should be noted that the manufacturing method of the pile fabric 1 according to the embodiments of the present invention includes a separation step S4 in addition to the weaving step S1, the heat treatment step S2 and the dissolving step S3, as the third embodiment.

[0139] <Weaving / Heat Treatment Process S1' etc.>

[0140] Furthermore, in the first to third embodiments described above, a weaving / heat treatment process S1' may also be included, which combines the weaving process S1 and the heat treatment process S2 into one process.

[0141] In detail, the weaving / heat treatment process S1' is configured as follows: the base fabric 2a and the back base fabric 2b, which have warp yarns 4 and weft yarns 5 respectively, are connected by the connecting yarn 3' fixed to two or more of the weft yarns 5, and the base fabric 2 and the pile yarn 3 are woven together, and the woven base fabric 2a and / or the woven back base fabric 2b are heat treated.

[0142] It should be noted that when the weaving process S1 and the heat treatment process S2 in the first embodiment become a weaving / heat treatment process S1', it can be said to be a variation of the first embodiment, which only has the weaving / heat treatment process S1'.

[0143] Similarly, in the case where the weaving process S1 and the heat treatment process S2 in the second embodiment become a weaving / heat treatment process S1', it can be said to be a variation of the second embodiment. This variation of the second embodiment includes a weaving / heat treatment process S1' and a melting process S3. The order of each process in the variation of the second embodiment is the order of weaving / heat treatment process S1' and melting process S3.

[0144] Furthermore, if the weaving process S1 and the heat treatment process S2 in the third embodiment become a single weaving / heat treatment process S1', it can be considered a variation of the third embodiment (see [reference]). Figure 13 (d)) The variation of the third embodiment includes a weaving / heat treatment process S1', a dissolving process S3 and a separating process S4, and the order of each process in the variation of the third embodiment is the order of weaving / heat treatment process S1', dissolving process S3 and separating process S4.

[0145] <Example>

[0146] like Figures 6 to 12 As shown, when the pile yarn 3 is secured by three weft yarns 5 (the middle weft yarn 5m is one), and 18 weft yarns 5 form a complete structure, if these 18 weft yarns 5 are numbered 1 to 18, then the pile yarn 3 with one side (front side) of the vertical setting part 3A and 3B of each pile yarn 3, which is the weft yarn 5 (one side weft yarn 5a) vertically set from the "frontmost and roughly central part (e.g., number 1, number 10)" of the back base fabric 2b, is designated as pile yarn 3-1. Similarly, the pile yarn 3 with one side vertical setting part 3A is designated as pile yarn 3-1. The pile yarn 3 vertically arranged on one side of the weft yarn 5a of the back base fabric 2b (e.g., No. 4, No. 13) is designated as pile yarn 3-2. The pile yarn 3 vertically arranged on one side from the weft yarn 5 (one side weft yarn 5a) of the frontmost and approximately central part (e.g., No. 1, No. 10) of the outer base fabric 2a is designated as pile yarn 3-3. The pile yarn 3 vertically arranged on one side from the weft yarn 5a of the front and approximately central part (e.g., No. 4, No. 13) of the outer base fabric 2a is designated as pile yarn 3-4.

[0147] In addition, Figure 6 , Figure 7 WW-oriented view (that is) Figure 12 In the backing fabric 2b, the warp yarns that clamp the pile yarns 3-1 and 3-3 from both sides (both sides of the length direction 5L of the weft yarn 5) and pass through the top of the weft yarn 5b on the other side are designated as warp yarns 4b-2 and 4b-3, and the warp yarns that clamp the pile yarns 3-2 and 3-4 from both sides and pass through the bottom of the weft yarn 5b on the other side are designated as warp yarns 4b-1 and 4b-4.

[0148] Furthermore, in Figure 6 , Figure 7 Looking at the WW direction, in the base fabric 2a, the warp yarns that clamp the pile yarns 3-1 and 3-3 from both sides and pass through the top of the weft yarn 5 (not any one of the weft yarns 5a on one side, 5b on the other side, 5m in the middle, and 5' of the soluble weft yarn) are also designated as warp yarns 4b-2 and 4b-3. The warp yarns that clamp the pile yarns 3-2 and 3-4 from both sides and pass through the bottom of the weft yarn 5 are also designated as warp yarns 4b-1 and 4b-4.

[0149] It should be noted that, as Figure 12As shown in (a) and (b), in the WW direction view (a side cross-sectional view showing the length direction of the warp yarn 4), the aforementioned pile yarns 3-1 to 3-4 are vertically arranged from the outer base fabric 2a and the back base fabric 2b, staggered from each other. After separating into the outer base fabric 2a and the back base fabric 2b, pile yarns 3-1 and 3-3 are vertically arranged from the back base fabric 2b, and pile yarns 3-2 and 3-4 are vertically arranged from the outer base fabric 2a. Alternatively, it can be said that the connecting yarn 3' in the weaving process S1 constitutes the vertical arrangement parts 3A and 3B in each pile yarn 3.

[0150] <Supporting Components>

[0151] The support member of the present invention is a component that supports a structure having the pile fabric 1 described herein and an elastic element and is curable.

[0152] In the support component, the pile fabric 1 is fixed to the outer surface of the elastic element in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic element (following the elastic deformation).

[0153] In addition, the support member may also have a protective member on the lower surface (underside) of the aforementioned elastic member.

[0154] First, the curable structure supported by such a support component will be described in detail.

[0155] <Cureable Structures>

[0156] The curable structure is a structure supported by the aforementioned support components.

[0157] The materials of curable structures can be cement-based curing materials such as cement or concrete, or any curable (or hardenable) materials such as asphalt.

[0158] The shape of the curable structure is not particularly limited. For example, it can be a block (such as a roughly rod-shaped pad) with a roughly trapezoidal cross-sectional shape (when viewed from the length direction), or a plate or ceramic tile with a roughly rectangular or roughly square shape when viewed from above. It should be noted that when the curable structure is a pad, the structure can also have a pair of left and right separate track fixing parts. Track fixing members are provided on the upper part of the pair of track fixing parts and are installed on both sides of the lower part (base) of each track. Furthermore, a support member is joined (fixed) to the bottom (lower side) of the structure serving as the pad. Additionally, the structure serving as the pad can also contain piano wire or steel rods (PC steel rods) as core material.

[0159] A curable structure can be supported by one support member, or by two or more support members, or by one support member supporting two or more curable structures, or by two or more support members supporting two or more support members (for example, support members having a length direction support curable structures having a length direction that are staggered from each other along that length direction).

[0160] In contrast to the curable structure described above, the pile yarn 3 of the pile fabric 1 in the support member is embedded (i.e., anchored) before the curable structure is cured (for example, during the period when the structure, which is a concrete pad, is in an unprocessed concrete state). After the curable structure is cured, the pile yarn 3 of the pile fabric 1 (i.e. the support member) is difficult to detach (difficult to peel off) or will not detach (peel off).

[0161] The following section provides a detailed explanation of the elastic components of the support parts that support such curable structures.

[0162] <Elastic component>

[0163] The elastic element is roughly plate-shaped and has elasticity. In addition, it may also have shock / vibration absorption properties.

[0164] The material of the elastic element can be, for example, a foam of ethylene propylene diene monomer (EPDM) or polyurethane, or a polyurethane foam formed by foaming polyurethane at a specified expansion ratio.

[0165] The shape of the elastic element is not particularly limited. For example, when the curable structure is a wooden block, it can be a similar shape that is slightly smaller than the bottom surface (lower surface) of the structure that serves as the wooden block when viewed from above, or it can be said that it is difficult to be exposed from the bottom surface of the structure that serves as the wooden block.

[0166] It should be noted that the thickness or strength of the elastic element is not particularly limited. For example, in the case where the curable structure is a wooden pad, the thickness or strength can be such that even if the load of a tram or train passing through the track is applied to the elastic element through the structure as a wooden pad, it will not be crushed or broken.

[0167] For such elastic elements, the aforementioned pile fabric 1 can also be fixed to the elastic element by bonding the base fabric 2 to the outer surface (upper outer surface) of the pre-formed elastic element using an adhesive. In this case, it can also be said that the adhesive is impregnated into the elastic element such as polyurethane foam for bonding, and simultaneously impregnated into the exposed portion of the back (lower surface) of the base fabric 2 formed by the warp yarns 4 or weft yarns 5, or the pile yarns 3.

[0168] In addition, when the elastic element is polyurethane foam, the elastic element can also be foamed and molded by placing the pile fabric 1 in a mold for molding the elastic element, thereby using the adhesive force of polyurethane to fix (bond) the pile fabric 1 to the outer surface (upper outer surface) of the elastic element.

[0169] <Protective Components>

[0170] The protective element is a sheet-like material that covers the lower surface (bottom side) of the elastic element.

[0171] The material of the protective component can also be, for example, a nonwoven fabric made of polyolefin synthetic resin fibers such as polypropylene (PP) fibers and polyethylene (PE) fibers.

[0172] <Manufacturing Method of Support Components>

[0173] The method for manufacturing a support member according to the present invention is a method for manufacturing a support member that supports a curable structure. The support member has a pile fabric 1 manufactured by the above-described manufacturing method and the above-described elastic element.

[0174] The manufacturing method of the support component includes: a fixing step, in which the pile fabric 1 is fixed to the outer surface of the elastic member in such a way that the base fabric 2 can deform according to the elastic deformation of the elastic member; and an embedding step, in which the pile yarn 3 of the pile fabric 1 is embedded in the curable structure.

[0175] In addition, the manufacturing method of the support component may also include a curing process, in which the curable structure is cured while the pile yarn 3 of the pile fabric 1 is embedded in the curable structure.

[0176] <Other>

[0177] This invention is not limited to the embodiments described above. The structure, shape, size, etc. of each component or the whole of the pile fabric 1, the method for manufacturing pile fabric 1, etc., can be appropriately modified in accordance with the spirit of this invention.

[0178] The pile fabric 1 can also be manufactured by a method other than the manufacturing method having the above-mentioned weaving process S1 and heat treatment process S2.

[0179] The pile yarn 3 can also pass under and be secured relative to the multiple adjacent weft yarns 5.

[0180] In this case, it can also be said that each pile yarn 3 constitutes a loose pile in a certain sense. In addition, in this case, it can also be said that each pile yarn 3 is not fixed to the warp yarn 4.

[0181] When the pile yarn 3 is secured relative to the adjacent weft yarns 5, the phrase "after passing under one or more of the adjacent weft yarns 5, then passing over another or more of the adjacent weft yarns 5" means that among the adjacent weft yarns 5, after passing under one or more of the first weft yarns 5, then passing over another or more of the first weft yarns 5; after passing under one or more of the second weft yarns 5, then passing over the second... When passing over one or more weft yarns 5, passing under one or more weft yarns 5 of the third, passing over another or more weft yarns 5 of the third, ..., passing under one or more weft yarns 5 of the nth, and then passing over another or more weft yarns 5 of the nth, the number of weft yarns 5 passing under or above the first, second, third, ..., nth can all be the same, or they can all be different, or only two can be the same, or only three can be the same, etc.

[0182] The warp yarn 4 can also be configured between each of the adjacent pile yarns 3 in the weft direction.

[0183] Alternatively, a synthetic resin such as an acrylic resin adhesive can be coated onto the back of the base fabric 2 to form a back coating (backing). It should be noted that... Figure 1 , Figure 2 The back of the base fabric 2 in the middle is not coated.

[0184] The manufacturing method of the pile fabric 1 can also include a backing process, as described above, of coating the back of the base fabric 2 with a synthetic resin such as an acrylic resin adhesive to form a backing coating (backing).

[0185] It should be noted that, when the backing process and the aforementioned dissolving process S3 and separating process S4 are included, the sequence of each process in this manufacturing method is: weaving process S1, heat treatment process S2 (or weaving / heat treatment process S1'), dissolving process S3, separating process S4, and backing process; or weaving process S1, heat treatment process S2 (or weaving / heat treatment process S1'), backing process, dissolving process S3, and separating process S4; or weaving process S1, dissolving process S3, heat treatment process S2, separating process S4, and backing process. If the manufacturing method includes this... If the backing process is present but lacks the dissolving process S3 and the separating process S4, then the sequence is: weaving process S1, heat treatment process S2 (or weaving / heat treatment process S1'), and backing process. Alternatively, if the backing process is present but lacks either the dissolving process S3 or the separating process S4, then the sequence is: weaving process S1, heat treatment process S2 (or weaving / heat treatment process S1'), dissolving process S or separating process S4, and backing process. Or, the sequence is: weaving process S1, heat treatment process S2 (or weaving / heat treatment process S1'), backing process, dissolving process S or separating process S4, etc.

[0186] (Industry availability)

[0187] The pile fabric and the pile fabric manufactured by the method of manufacturing pile fabric of the present invention have pile yarn 3 (pile loop portion) that is generally rectangular (that is, not sharp). Therefore, in addition to being used as a pile fabric in general applications such as brushes that come into contact with the human body, the inside of shoes (slippers, etc.) used in the bathroom, shoe insoles (parts where the pile yarn comes into contact with the sole of the foot), and hook and loop fasteners, it can also be used in any product such as industrial materials.

[0188] The support member and the support member manufactured by the method of manufacturing the support member according to the present invention can be used in any product, such as for supporting curable structures, in addition to supporting solidifiable structures.

Claims

1. A method for manufacturing a pile fabric, wherein pile yarns (3) are vertically arranged from a base fabric (2), characterized in that, have: In the weaving / heat treatment process (S1'), the base fabric (2a) and the back base fabric (2b), which respectively have warp yarns (4) and weft yarns (5), are connected by connecting yarns (3') secured to two or more of the weft yarns (5), the base fabric (2) and the pile yarns (3) are woven, and the woven base fabric (2a) and / or the woven back base fabric (2b) are heat treated; and In the dissolving process (S3), the weft yarn (5) contains soluble fibers, and the dissolving process (S3) dissolves the soluble fibers. The connecting yarn (3') is formed into the pile yarn (3), the front end of the pile yarn (3) is U-shaped when viewed from the side, and the base end is upright relative to the base fabric (2) when viewed from the side. In the pile fabric prior to the dissolving process (S3), The pile yarn (3) is secured to three or more adjacent weft yarns (5) in the warp direction, where the warp direction is the length direction of the warp yarns (4). The pile yarn (3), relative to the three or more adjacent weft yarns (5), passes under one or more of the adjacent three or more weft yarns (5), then passes over the other multiple weft yarns (5), and then passes under another or more of the adjacent three or more weft yarns (5) and is thus secured. The one or more weft yarns (5) include the weft yarn (5a) located on the side closest to the three or more adjacent weft yarns (5). The other or more weft yarns (5) include the weft yarn (5b) located on the last side of the three or more adjacent weft yarns (5). The additional multiple weft yarns (5) include an intermediate weft yarn (5m) located between these one-sided weft yarns (5a) and the other-sided weft yarns (5b), and a soluble weft yarn (5') having only the soluble fibers.

2. The method for manufacturing pile fabric according to claim 1, characterized in that, In the pile fabric after the dissolving process (S3), The traces of the woven yarn (3) being stuck to the soluble weft yarn (5') disappear, and it becomes roughly rectangular.

3. The method for manufacturing pile fabric according to claim 1, characterized in that, In the pile fabric after the dissolving process (S3), There is a place where the soluble weft yarn (5') exists between the other weft yarn (5b) and the middle weft yarn (5m).

4. A pile fabric, characterized in that... ， Manufactured according to the manufacturing method of claim 1.

5. A pile fabric, wherein pile yarns (3) are vertically arranged from a base fabric (2), characterized in that, The base fabric (2) has warp yarns (4) and weft yarns (5). The pile yarn (3) is secured to one or more weft yarns (5). The front end of the pile yarn (3) is U-shaped when viewed from the side, and the base end is upright relative to the base fabric (2) when viewed from the side. The pile yarn (3) is secured to three or more adjacent weft yarns (5) in the warp direction, where the warp direction is the length direction of the warp yarns (4). The pile yarn (3), relative to the three or more adjacent weft yarns (5), passes under one or more of the three or more adjacent weft yarns (5), then passes over another or more of the three or more adjacent weft yarns (5), and then passes under another or more of the three or more adjacent weft yarns (5) and is thus locked in place. The one or more weft yarns (5) include the weft yarn (5a) located on the side closest to the three or more adjacent weft yarns (5). The other or more weft yarns (5) include the weft yarn (5b) located on the last side of the three or more adjacent weft yarns (5). The other or more weft yarns (5) include an intermediate weft yarn (5m) located between these one-sided weft yarns (5a) and the other-sided weft yarns (5b). Between the other weft yarn (5b) and the middle weft yarn (5m), there exists a soluble weft yarn (5') containing only soluble fibers.

6. A support member for supporting a curable structure, said support member having the pile fabric (1) as described in claim 1 and a plate-shaped elastic element, characterized in that, The pile fabric (1) is fixed to the outer surface of the elastic element in such a way that the base fabric (2) can deform according to the elastic deformation of the elastic element. The pile yarn (3) of the pile fabric (1) is embedded in the curable structure.

7. The support component according to claim 6, characterized in that, The curable structure is a wooden pad with a roughly trapezoidal cross-sectional shape when viewed along its length. The wooden pad has a pair of left and right track fixing parts that are separated. A track fixing component is provided on the upper part of the pair of left and right track fixing parts. On the lower side of the wooden block, a support member is fixed to support the wooden block. The elastic element is a foam.

8. A method for manufacturing a support member, the support member supporting a curable structure, the support member having a pile fabric (1) manufactured by the manufacturing method of claim 1 and a plate-shaped elastic element, characterized in that, have: In the fixing process, the pile fabric (1) is fixed to the outer surface of the elastic member in such a way that the base fabric (2) can deform according to the elastic deformation of the elastic member; as well as In the embedding process, the pile yarn (3) of the pile fabric (1) is embedded in the curable structure.

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