KNITWEAR AND FIBER PRODUCT

Description

Technical Field

[0001] The present invention relates to a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties.Background Art

[0002] Polyester filament fibers typified by polyethylene terephthalate (PET) are widely used for clothing, industrial materials, and the like. However, due to characteristics of a manufacturing method thereof, they involve such defects that as compared with natural fibers and spun yarns, the thickness unevenness is small, and the texture and the appearance change are poor.

[0003] In order to eliminate such defects, there is proposed a method for imparting thickness unevenness to a polyester fiber by controlling the length of an unstretched portion of a highly oriented polyester unstretched yarn, thereby imparting an arbitrary splashed pattern-like appearance to the fabric (see, for example, Patent Literature 1 and Patent Literature 2).

[0004] However, it could not be said that such a fabric is satisfactory in terms of cotton-like appearance, snagging resistance, and so on.

[0005] Patent Literature 3 relates to a composite textured yarn containing a component yarn A and a component yarn B each false twisted and crimped.

[0006] Patent Literature 4 relates to a composite crimped yarn comprising: at least two kinds of multifilament yarns, one of them being comprised of a crimped conjugate multifilament yarn comprising two kinds of polyester polymers different from each other in the heat shrinkability and positioned as a major component of the inner layer of the composite crimped yarn, the other of them being comprised of a crimped multifilament yarn of a single synthetic polymer and positioned as a major component in the outer layer of the composite crimped yarn.

[0007] Patent Literature 5 relates to a polyester composite false-twisted yarn comprising a thick- thin polyester yarn having irregular thickness in the longitudinal direction of the yarn and a polyester drawn yarn having a dyeing property different from that of the thick-thin yarn.

[0008] Patent Literature 6 relates to a knitted fabric obtained by affording a combined filament yarn using a multifilament yarn having ≤0.9 dtex single filament fineness and a thick and thin yarn having a higher shrinkage percentage in boiling water than that of the multifilament yarn and dyeable to a dark color, then knitting the resultant combined filament yarn and other yarns having a lower shrinkage percentage in boiling water than that of the combined filament yarn and subsequently carrying out dyeing processing.Citation ListPatent Literature

[0009] Patent Literature 1: JP 60-199941 A Patent Literature 2: JP 7-229030 A Patent Literature 3: EP 0777002 A2 Patent Literature 4: EP 0535878 A1 Patent Literature 5: JP 2001003233 A Patent Literature 6: JP 2006152495 A Summary of InventionTechnical Problem

[0010] In view of the aforementioned background, the present invention has been made, and an object thereof is to provide a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties.Solution to Problem

[0011] In order to achieve the aforementioned problem, the present inventors made extensive and intensive investigations, and as a result, they have led to accomplishment of the present invention.

[0012] Thus, in accordance with the present invention, a knitted fabric comprising a composite yarn comprising a non-crimped thick and thin yarn and a crimped yarn is provided. The knitted fabric has a density of 35 to 100 courses / 2.54 cm and 30 to 100 wales / 2.54 cm. In addition, it is preferred that the composite yarn contains the aforementioned thick and thin yarn in a ratio within a range of 30 to 85% by weight relative to the weight of the composite yarn. The thick and thin yarn and the crimped yarn are aligned and interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state. In addition, in the composite yarn, it is preferred that the non-aligned part is 40 to 95% relative to the length of the composite yarn. In addition, in the composite yarn, it is preferred that the aligned part is 5 to 40% relative to the length of the composite yarn. In addition, it is preferred that the thick and thin yarn and / or the crimped yarn is made of a polyester fiber or a nylon fiber. In addition, it is preferred that the thick and thin yarn and / or the crimped yarn is made of a cationic dyeable polyester. In addition, it is preferred that in the thick and thin yarn and / or the crimped yarn, the content of a matting agent is 0.1% by mass or more.

[0013] In addition, it is preferred that a snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.

[0014] In addition, in accordance with the present invention, a fiber product made of the aforementioned fabric, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding, is provided.Advantageous Effects of Invention

[0015] In accordance with the present invention, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties are obtained.Description of Embodiments

[0016] Embodiments of the present invention are hereunder described in detail. First, the composite yarn of the present invention is a composite yarn containing a thick and thin yarn and a crimped yarn.

[0017] Here, it is preferred that the composite yarn contains the thick and thin yarn in a ratio within a range of 30 to 85% by weight (more preferably 51 to 80% by weight) relative to the weight of the composite yarn. In addition, it is preferred that a weight ratio of the crimped yarn (relative to the weight of the composite yarn) is within a range of 15 to 70% by weight (more preferably 30 to 48% by weight). In the case where the weight ratio of the thick and thin yarn (relative to the weight of the composite yarn) is smaller than the foregoing range, there is a concern that the excellent cotton-like appearance is not obtained. In addition, in the case where the weight ratio of the thick and thin yarn is larger than the foregoing range, there is a concern that the snagging resistance of the fabric is lowered.

[0018] The thick and thin yarn is a non-crimped yarn. When the thick and thin yarn is a non-crimped yarn, in view of the fact that a difference in crimp between the thick and thin yarn and the crimped yarn is large, the thickness unevenness in the composite yarn becomes large, and excellent cotton-like appearance and texture are developed. In addition, in the case where the non-crimped yarn is disposed in a core of the composite yarn, and the crimped yarn is disposed in a sheath of the composite yarn, the water absorbing and quick drying properties are improved due to capillary phenomenon.

[0019] Examples of the thick and thin yarn include a thick and thin yarn having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers as described in JP 2000-234232 A; and a thick and thin yarn obtained by non-homogeneous stretching using a frictional resistor as described in JP 7-324237 A.

[0020] On the other hand, though the crimped yarn may be a crimped yarn in which latent crimp of side-by-side type conjugate fiber is visualized, it is preferably a false-twist crimped textured yarn.

[0021] The type of the polymer forming the thick and thin yarn and / or the crimped yarn is preferably a polyester or an aliphatic polyamide (e.g., nylon 6 and nylon 66). Above all, there are more preferably exemplified polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, and a polyester resulting from copolymerization with a third component. Such a polyester may also be a material recycled or chemical recycled polyester. Furthermore, the polyester may also be a polyester obtained by using a catalyst containing specified phosphorus compound and titanium compound as described in JP 2004-270097 A and JP 2004-211268 A. If desired, the polyester polymer may contain therein one or more of a micropore forming agent, a cationic dye dyeable agent, a coloring inhibitor, a thermal stabilizer, a fluorescent brightening agent, a matting agent, a coloring agent, a moisture absorbent, and inorganic fine particles within a range where the object of the present invention is not hindered. In particular, when the matting agent is contained in a ratio of 0.1% by weight or more (more preferably 0.3 to 2.0% by weight) relative to the weight of the polymer, the see-through-preventing properties are improved, and hence, such is preferred. Specifically, a semi dull polyester and a full dull polyester are preferred. In addition, when the cationic dye dyeable agent (e.g., a polyester-forming sulfonic acid metal salt compound is contained), antibacterial and deodorization properties are added by performing an acid treatment as described in WO 2011 / 048888 A, and hence, such is preferred.

[0022] In the thick and thin yarn, a total fineness thereof is preferably 22 to 400 dtex (more preferably 30 to 60 dtex) . In addition, a single fiber fineness of the thick and thin yarn is preferably 1.5 dtex or more (more preferably 1.5 to 3.0 dtex). In addition, a filament number of the thick and thin yarn is preferably 12 to 200 (more preferably 20 to 60).

[0023] In the crimped yarn, from the standpoint of obtaining the excellent cotton-like appearance and snagging resistance, a total fineness thereof is preferably smaller than that of the thick and thin yarn. In particular, the total fineness of the crimped yarn is preferably 18 to 333 dtex (more preferably 20 to 50 dtex). In addition, a single fiber fineness of the crimped yarn is preferably 1.0 dtex or less (more preferably 0.1 to 1.0 dtex). In addition, a filament number of the crimped yarn is preferably 12 to 200 (more preferably 20 to 60). In addition, a crimp degree of the crimped yarn is preferably within a range of 2 to 40% (more preferably 5 to 35%).

[0024] Although the composite yarn of the present invention is preferably constituted of only the thick and thin yarn and the crimped yarn, it may contain other fibers. In addition, the thick and thin yarn and the crimped yarn can be aligned and interlaced (air-mixed).

[0025] On that occasion, an interlace number is preferably within a range of 200 or less per meter (more preferably 120 or less per meter, and especially preferably 20 to 120 per meter).

[0026] In the composite yarn, the thick and thin yarn and the crimped yarn are interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state. Such a composite yarn is, for example, obtained by obtaining a thick and thin yarn having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers according to the method as described in Example 1 of JP 2000-234232 A, followed by aligning the thick and thin yarn and the crimped yarn and interlacing.

[0027] Here, in the composite yarn, it is preferred that the non-aligned part is 40 to 95% relative to the length of the composite yarn. In addition, in the composite yarn, it is preferred that the aligned part is 5 to 40% relative to the length of the composite yarn. However, it is to be noted that each of those ratios is one obtained by extracting 10 composite yarns (20 cm) from the fabric, calculating each of the ratios relative to the composite yarn (20 cm), and then determining an average of the 10 yarns.

[0028] The fabric of the present invention contains the aforementioned composite yarn. In such a fabric, the structure of the fabric is not limited, and is obtained by knitting by a usual method. Examples of the knitted fabric include jersey stitch and half textures, half-base textures, or satin textures obtained using 2 reeds or 3 reeds. The knitted fabric has a density of 35 to 100 courses / 2.54 cm and 30 to 100 wales / 2.54 cm providing water absorbing and quick drying properties.

[0029] A basis weight of the fabric is preferably within a range of 70 to 130 g / m 2< .

[0030] To such a fabric, dyeing, water absorption, embossing, coloring and printing, and water repellent finishing, and various processings imparting functions of a UV shielding agent, an antibacterial agent, a deodorant, an insect repellent, a luminous agent, a retroreflector, and a minus ion generating agent, may be additionally applied.

[0031] The thus obtained fabric has excellent cotton-like appearance, excellent texture, snagging resistance, see-through-preventing properties, and water absorbing and quick drying properties. On that occasion, it is preferred that the snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.

[0032] Next, the fiber product of the present invention is a fiber product made of the aforementioned fabric, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding.

[0033] Since such a fiber product uses the aforementioned fabric, it is excellent in cotton-like appearance, snagging resistance, see-through-preventing properties, and water absorbing and quick drying properties.Examples

[0034] Next, the present invention is described in detail by reference to Examples, but it should be construed that the present invention is by no means limited by these Examples.(1) Basis Weight

[0035] The basis weight (g / m 2< ) of a woven fabric was measured by JIS L1096-2010.(2) Snagging Resistance

[0036] The test was performed for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method.(3) Crimp Degree

[0037] The crimp degree was measured by the following method.

[0038] That is, a test filament thread is wound around a sizing reel having a peripheral length of 1.125 m to prepare a skein having a dry fineness of 3333 dtex.

[0039] The skein is hung on a hanger nail of a scale plate. An initial load of 6 g is applied to the lower part thereof, and a further load of 600 g is applied; and the skein length at that time is measured as L0. The load is then immediately removed from the skein, and the skein is removed from the hanger nail of the scale plate and immersed in boiling water for 30 minutes, thereby allowing crimps to be developed. The skein treated with boiling water is taken out from boiling water, and moisture contained in the skein is removed by absorption on a filter paper. The skein is then air-dried for 24 hours at room temperature. The air-dried skein is hung on a hanger nail of a scale plate. A load of 600 g is applied to the lower part thereof, and the skein length is measured after 1 minute as L1a. The load is then removed from the skein, and the skein length is measured after 1 minute as L2a. The crimp degree (CP) of the test filament thread is calculated according to the following equation. CP % = L 1 a − L 2 a / L 0 × 100(4) Degree of Interlace

[0040] An interlaced yarn is taken by a length of 1 m under a load of 8.82 mN × (nominal tex) (0.1 g / de), and after removing the load, the yarn is allowed to contract at room temperature for 24 hours, followed by reading the number of nodes, a value of which is indicated in terms of nodes / m.(5) Ratios of Non-Aligned Part and Aligned Part in Composite Yarn

[0041] Ten composite yarns (20 cm) were extracted from the fabric, each of the ratios relative to the composite yarn (20 cm) was calculated, and an average of the 10 yarns was determined.(6) Spun-Like Appearance

[0042] The spun-like appearance was evaluated according to criteria of three stages of "o" (excellent), "Δ" (moderate), and "×" (inferior) by visual judgment by the tester.[Examples 1 to 5 and Comparative Examples 1 to 2]

[0043] Non-crimped thick and thin yarns as shown in Table 1 each having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers were obtained according to the method described in Example 1 of JP 2000-234232 A. In addition, in Examples 1 to 5, the false-twist crimped textured yarn shown in Table 1 was obtained by a conventional method. In Table 1, "FD" indicates a chemical recycled full dull polyester; "SD" indicates a chemical recycled semi dull polyester; and "CD" indicates a chemical recycled cationic dyeable polyester. In addition, for example, the term "44T36" means one having a total fineness of 44 dtex and a filament number of 36.

[0044] Subsequently, in Examples 1 to 5, the thick and thin yarn and the false-twist crimped textured yarn were aligned and interlaced, thereby obtaining a composite yarn in which the thick and thin yarn and the crimped yarn were interlaced with each other, or in which a non-aligned part where the thick and thin yarn was located in a core and the crimped yarn was located in a sheath was intermingled with an aligned part where the thick and thin yarn and the crimped yarn were in an aligned state. Subsequently, knitted fabrics were obtained using a circular knitting machine as shown in Table 1.

[0045] In Example 1, the non-aligned part was 74%, and the aligned part was 26%. The evaluation results of Examples 1 to 5 and Comparative Examples 1 to 2 are shown in Table 1. Table 1Example 1Example 2Example 3Comparative Example 1Comparative Example 2Example 4Example 5YarnThick and thin yarnFD44T36FD44T36FD44T36FD110T36FD66T72FD33T36FD33T36False-twist crimped textured yarnYarn typeFD33T36SD33T72CD33T36--FD44T36FD33T36Crimp degree (%)26615--2540IL number (per meter)1009898--110123Total fineness77T7277T10877T72110T3666T72FD77T72FD77T72Knitted fabricType of knitting machine (gauge)46G single46 G single28G single28G28G46G46GStructureJersey stitchJersey stitchJersey stitchJersey stitchJersey stitchJersey stitchJersey stitchBasis weight (g / m 2< )11511389115105110110Course (per 2.54 cm)82756455907979Wale (per 2.54 cm)66725445737070Snagging (D-3 Method, grade)4.54.54.5114.54.5Spun-like appearance○○○××ΔΔ Industrial Applicability

[0046] In accordance with the present invention, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties are provided, and an industrial value thereof is extremely large.

Claims

1. A fabric comprising a composite yarn comprising a thick and thin yarn and a crimped yarn, wherein the thick and thin yarn is a non-crimped yarn, and wherein the fabric is a knitted fabric having a density of 35 to 100 courses / 2.54 cm and 30 to 100 wales / 2.54 cm, wherein in the composite yarn, the thick and thin yarn and the crimped yarn are aligned and interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state.

2. The fabric according to claim 1, wherein the composite yarn contains the thick and thin yarn in a ratio within a range of 30 to 85% by weight relative to the weight of the composite yarn.

3. The fabric according to claim 2, wherein in the composite yarn, the non-aligned part is 40 to 95% relative to the length of the composite yarn, wherein the ratio is one obtained by extracting 10 composite yarns with a length of 20 cm from the fabric, calculating each of the ratios relative to the composite yarn with a length of 20 cm, and then determining an average of the 10 yarns.

4. The fabric according to claim 2, wherein in the composite yarn, the aligned part is 5 to 40% relative to the length of the composite yarn, wherein the ratio is one obtained by extracting 10 composite yarns with a length of 20 cm from the fabric, calculating each of the ratios relative to the composite yarn with a length of 20 cm, and then determining an average of the 10 yarns.

5. The fabric according to any of claims 1 to 4, wherein the thick and thin yarn and / or the crimped yarn is made of a polyester fiber or a nylon fiber, preferably wherein the thick and thin yarn and / or the crimped yarn is made of a cationic dyeable polyester.

6. The fabric according to any of claims 1 to 5, wherein in the thick and thin yarn and / or the crimped yarn, the content of a matting agent is 0.1% by mass or more.

7. The fabric according to any of claims 1 to 6, wherein a snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.

8. A fiber product made of the fabric according to any of claims 1 to 7, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding.