Covering yarn to be used by unwinding wound yarn

Abstract

To provide a covering yarn to be used by unwinding a wound yarn, which expresses sufficient yarn length difference equal to or more than length difference between two yarns after unwinding the wound yarn.SOLUTION: A covering yarn includes a core yarn and one or more wound yarns wound around the core yarn. Breaking strength of the core yarn and the wound yarn is 2cN / dtex or more. At least an outermost wound yarn is a false-twisted yarn or a composite yarn including the false-twisted yarn. Ratio of the length of at least the outermost wound yarn to the length of the core yarn is 1.20 to 2.00. The outermost wound yarn has torque and is wound in an opposite direction to the torque. Crimp stretch ratio of at least the outermost wound yarn is 10% or more in the covering yarn to be used by unwinding the wound yarn.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a covering yarn for unwinding and using a wound yarn.

Background Art

[0002] Elastic fibers are used to obtain stretchable woven or knitted fabrics such as foundations, stockings, sportswear, and swimsuits. As such elastic fibers, polyurethane-based elastic yarns, also called spandex fibers, and covering yarns manufactured by winding long fibers made of polyamide around elastic yarns, in which the drawbacks (dyeing characteristics, mechanical strength, and abrasion resistance characteristics) of the polyurethane-based elastic yarns are eliminated, are used.

[0003] Various contrivances have been made to the covering yarn so as not to impair the performance of the elastic fiber to be wound, not to impair the handleability when the covering yarn is woven or knitted, not to cause defects in the knitted fabric using the covering yarn, and further to maintain the aesthetic property.

[0004] For example, in Patent Document 1, in a method of manufacturing a double covering elastic yarn by doubly winding two covering yarns made of long fibers of a thermoplastic polymer around a core yarn made of an elastic fiber while changing the winding direction, as the inner covering yarn, a non-bulky torque-type false-twisted yarn having a torque in the direction opposite to the winding direction is used. A method for manufacturing a double covering elastic yarn has been proposed. According to the study by the present inventors, in prior art documents disclosing proposals for the above-mentioned contrivances, including Patent Document 1, it is not assumed that the wound yarn of the covering yarn is unwound after manufacturing the covering yarn, for example, after weaving or knitting using the covering yarn.

[0005] In the case of the other party, Patent Document 2 proposes a method for manufacturing a two-stage cut pile product, which is characterized in that a covering yarn obtained by overfeeding a yarn strip in which at least one kind is untwisted is used as a pile yarn for tufting to form a cut pile, and then subjected to a fiber opening treatment to create a yarn length difference with two or more kinds of yarn strips.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, according to the study by the present inventors, in the manufacturing method of Patent Document 2, since a covering yarn (i.e., an untwisted sliver) obtained by overfeeding an untwisted yarn strip is used, the shedding of short fibers is intense during the fiber opening treatment, and floating hairs remain in the two-stage cut pile product. Furthermore, although the manufacturing method of the same document can manufacture a cut pile product having a two-stage step, the variation in the length of the long cut pile with respect to the length of the short cut pile is large.

[0008] An object of the present invention is to provide a covering yarn for unwinding and using a wound yarn, which exhibits a sufficient yarn length difference of two or more stages after unwinding the wound yarn.

Means for Solving the Problems

[0009] As a result of intensive studies by the present inventors, it has been found that the above problems can be solved by a covering yarn having a specific structure. That is, the present invention includes the following preferred embodiments. [1] A covering yarn comprising a core yarn and one or more winding yarns wound around the periphery thereof, wherein the breaking strength of the core yarn and the winding yarns is 2 cN / dtex or more, at least the outermost winding yarn is a false-twist yarn or a composite yarn comprising a false-twist yarn, the ratio of the length of at least the outermost winding yarn to the length of the core yarn is 1.20 to 2.00, the outermost winding yarn has torque and is wound in the direction opposite to the torque, and the crimp elongation rate of at least the outermost winding yarn is 10% or more, the covering yarn for unwinding and using the winding yarn. [2] The covering yarn according to [1], wherein the fineness of the core yarn is 165 dtex or more. [3] The covering yarn according to [1] or [2], wherein the fineness of the winding yarn is 165 dtex or more. [4] The covering yarn according to any one of [1] to [3], wherein the covering yarn is a single covering yarn. [5] The covering yarn according to any one of [1] to [3], wherein the covering yarn is a double covering yarn, the inner winding yarn has torque and is wound in the direction opposite to its own torque. [6] The covering yarn according to any one of [1] to [3], wherein the covering yarn is a double covering yarn, the inner winding yarn has torque and is wound in the same direction as its own torque. [7] The covering yarn according to any one of [1] to [3], [5] and [6], wherein all the winding yarns are false-twist yarns or composite yarns comprising false-twist yarns. [8] The covering yarn according to any one of [1] to [3] and [5] to [7], wherein the inner winding yarn and the outer winding yarn are wound in opposite directions. [9] Regarding the winding yarn when the covering yarn is a single covering yarn, or the inner winding yarn when the covering yarn is a double covering yarn, the relationship among the fineness D1 of the core yarn, the fineness D2 of the winding yarn, and the covering number T1 of the winding yarn is the following formulas (I) to (III): When 330 dtex ≤ total fineness < 1000 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <12000 (I) When 1000 dtex ≤ total fineness < 1350 dtex, 9000 ≤ T1 × (total fineness)1 / 2 <23500 (II) When 1350 dtex ≤ total fineness < 1760 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <30000 (III) [In formulas (I) to (III), the total fineness is D1 + D2, where 165 dtex ≤ D1 ≤ 1100 dtex and 165 dtex ≤ D2 ≤ 660 dtex] The covering yarn according to any one of [1] to [8], represented by any one of the following

[10] Regarding the outer winding yarn in the case where the covering yarn is a double covering yarn, the relationships among the fineness D1 of the core yarn, the fineness D2 of the inner winding yarn, the fineness D3 of the outer winding yarn, and the covering number T2 of the outer winding yarn are as follows in formulas (IV) to (VII): When 495 dtex ≤ total fineness < 1100 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <18700 (IV) When 1100 dtex < total fineness < 1400 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <22000 (V) When 1400 dtex < total fineness < 1600 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <26000 (VI) When 1650 dtex < total fineness < 2420 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <28500 (VII) [In formulas (IV) to (VII), the total fineness is D1 + D2 + D3, where 165 dtex ≤ D1 ≤ 1100 dtex, 165 dtex ≤ D2 ≤ 660 dtex, and 165 dtex ≤ D3 ≤ 660 dtex] The covering yarn according to any one of [1] to [3] and [5] to [9], represented by any one of the following

[11] The covering yarn according to any one of [1] to

[10] for producing a pile fabric

Effect of the Invention

[0010] According to the present invention, it is possible to provide a covering yarn for unwinding a wound yarn and using it, which exhibits a sufficient yarn length difference of two or more stages after unwinding the wound yarn.

Brief Description of Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described in detail. Note that there is no intention to limit the present invention to the following embodiments.

[0013] [Covering Yarn] The covering yarn of the present invention includes a core yarn and one or more wound yarns wound around the periphery thereof. Further, the covering yarn of the present invention is a covering yarn for unwinding at least the outermost wound yarn and using it. The present inventors have found that by using a specific core yarn and a specific wound yarn and winding at least the outermost wound yarn in a specific direction so that the ratio of the length of at least the outermost wound yarn to the length of the core yarn is within a specific range, at least the outermost wound yarn can be unwound well from the core yarn.

[0014] Since the winding yarn is wound around the core yarn, when the winding yarn is unwound, its length becomes longer than the length of the core yarn. That is, for example, when the covering yarn is a single covering yarn, a two-step yarn length difference (the difference between the length of the core yarn and the length of the winding yarn) appears after unwinding the winding yarn. For example, when the covering yarn is a double covering yarn, a three-step yarn length difference (the difference between the length of the core yarn, the length of the inner winding yarn, and the length of the outer winding yarn) appears after unwinding all the winding yarns. For example, when the covering yarn is a double covering yarn and only the outer winding yarn is unwound, a two-step yarn length difference (the difference between the length of the core yarn and the length of the outer winding yarn) appears after unwinding the outer winding yarn. In the covering yarn of the present invention, the ratio of the length of at least the outermost winding yarn to the length of the core yarn is 1.20 or more. If the ratio is less than 1.20, a sufficient yarn length difference of two steps or more cannot appear after unwinding the winding yarn. The ratio is preferably 1.21 or more, more preferably 1.30 or more, still more preferably 1.40 or more, and particularly preferably 1.50 or more. When the ratio is equal to or greater than the lower limit value, a sufficient yarn length difference of two steps or more can appear after unwinding the winding yarn.

[0015] Due to the appearance of this sufficient yarn length difference, for example, when the covering yarn of the present invention is used for the cut pile yarn of a raised fabric (cut pile raised fabric), the yarn length of the cut pile yarn can be made sufficiently longer than the yarn length after cutting (and before the fibrillation process). In the finishing process of the raised fabric, a process of fibrillating (also called hair splitting) the fibers of the cut pile yarn with a card cloth or the like is usually incorporated to improve the texture and express a voluminous feeling. The textured yarns that have been used in the production of raised fabrics so far have not been expected to exhibit a yarn length that is sufficiently longer than the yarn length of the cut pile yarn before fibrillation, even if the yarn is loosened in the fibrillation process. For example, a Meyer blanket is a fabric that exhibits a raised state by raising the reverse cut pile surface, but it has not been possible to exhibit a raised state longer than the length of the cut pile standing on the cut pile surface. However, by using the covering yarn of the present invention for the cut pile yarn of the raised fabric, the yarn length of the cut pile yarn after the fibrillation process can be made sufficiently longer than the yarn length of the cut pile yarn before (and after cutting) the fibrillation process. In addition, in order to change the yarn length of the cut pile yarn, it is usually necessary to change the settings of the raised fabric manufacturing apparatus, and this change requires a great deal of man-hours. However, by using the covering yarn of the present invention, the yarn length of the cut pile yarn can be easily changed without changing the settings of the manufacturing apparatus. Further, a dedicated raised fabric manufacturing apparatus is required for manufacturing a long-haired raised fabric, which has been a bottleneck in manufacturing a long-haired raised fabric. However, by using the covering yarn of the present invention, a long-haired raised fabric can be manufactured with a general raised fabric manufacturing apparatus without using such a dedicated apparatus, and thereby the problem of the bottleneck can also be solved. Further, when a cut pile with a long pile length is required, usually, due to the mechanism of the manufacturing apparatus, the production speed decreases as the pile length increases. However, by using the covering yarn of the present invention, such a decrease in the production speed can be avoided. Also, the yarn length difference between the core yarn and the winding yarn is manifested by the unwinding of the winding yarn. And the winding yarn can be unwound well as desired, that is, without being accompanied by the dropping-off of the core yarn and the winding yarn and the excessive elongation of the core yarn and the winding yarn. Therefore, there is little or small variation in the length of the long yarn (unwound winding yarn) with respect to the length of the short yarn (core yarn), and a uniform yarn length difference can be achieved.

[0016] On the other hand, in the covering yarn of the present invention, the ratio of the length of at least the outermost winding yarn to the length of the core yarn is 2.00 or less. When the ratio is greater than 2.00, the unwinding of the winding yarn tends to become difficult. The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn (the thickness of the core yarn, the thickness of the winding yarn, the covering number of the winding yarn (the number of rotations of the winding yarn per 1 meter of the covering yarn), and the magnitude of the torque of the winding yarn). From the viewpoint of ease of unwinding, the ratio is preferably 1.90 or less (for example, 1.80 or less or 1.70 or less).

[0017] For example, when the covering yarn is a double covering yarn and there are multiple winding yarns, the ratio of the length of the inner winding yarn that is not unwound or not intended to be unwound to the length of the core yarn may preferably be 1.05 or more (for example, 1.06 or more, 1.07 or more, or 1.08 or more). The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn. From the viewpoints of productivity and / or appearance after unwinding, it is preferably 3.00 or less (for example, 2.50 or less or 2.00 or less). In one embodiment of the present invention, the ratio of the length of the inner winding yarn whose unwinding is intended to the length of the core yarn may preferably be 1.07 or more (for example, 1.08 or more, 1.09 or more, or 1.10 or more) from the viewpoints of a sufficient yarn length difference between the core yarn and the inner winding yarn and unwindability. The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn. From the viewpoint of ease of unwinding, the ratio is preferably 1.80 or less (for example, 1.70 or less or 1.60 or less).

[0018] The ratio of the length of the winding yarn to the length of the core yarn is obtained by unwinding the winding yarn while applying a certain tension without excessively stretching the core yarn and the winding yarn, measuring the lengths of the core yarn and the winding yarn respectively, and calculating the ratio. More specifically, it can be measured by the method described in the examples below.

[0019] The ratio of the length of the winding yarn to the length of the core yarn can be adjusted to be not less than the lower limit value and not more than the upper limit value by, for example, selecting the fineness of the core yarn, the fineness of the winding yarn, the covering number of the winding yarn, and / or the helix angle of the winding yarn. An example of the above ratio adjustment method will be described using the case of manufacturing a single covering yarn. Fig. 1 shows a schematic diagram showing the arrangement of the core yarn 2 and the winding yarn 3. The left figure in Fig. 1 is a schematic cross-sectional view when the covering yarn is cut in a direction perpendicular to the longitudinal direction of the single covering yarn. The central figure in Fig. 1 is a schematic diagram when the winding yarn 3 (ends are A and B) is wound around the core yarn 2 at the helix angle θ1 (radian) of the winding yarn, and the right figure in Fig. 1 is a schematic diagram of the winding yarn before winding the winding yarn 3 (ends are A' and B') around the core yarn 2 at the helix angle θ1 of the winding yarn. In addition, in Fig. 1 and Figs. 3 and 4 described later, for ease of viewing the drawings, the dimensions, ratios, etc. of each component are appropriately different. Since the line segment A'C corresponds to (diameter of winding yarn 3 + diameter of core yarn 2 + diameter of winding yarn 3)×π, and the line segment B'C corresponds to 1 / T (T [t / m] is the covering number of the winding yarn 3), tanθ1 is expressed by the following formula. tanθ1=(1 / T) / {(diameter of winding yarn 3 + diameter of core yarn 2 + diameter of winding yarn 3)×π} When the core yarn and the winding yarn are made of polyester, the relationship between the fineness of polyester and the diameter d is generally expressed by the following formula. At this time, 1.38 is used as the specific gravity of polyester. d [μm]=10×(fineness) 1 / 2 Then, when the fineness of the core yarn is D1 (denier), the fineness of the winding yarn is D2 (denier), and the covering number of the winding yarn is T×10 -6 (t / μm), tanθ1 is expressed by the following formula (1). tanθ1=1 / {T×10 -6 ×(10×D2 1 / 2 +10×D1 1 / 2 +10×D2 1 / 2 )×π} =1 / {10 -5 ×π×T×(D1 1 / 2 +2×D2 1 / 2 )} Formula (1) In addition, when the core yarn or the winding yarn is made of nylon (specific gravity: 1.14) or olefin (specific gravity: 0.91 - 0.98), the relationship between the fineness and the diameter d is generally the following formula: d [μm]=11×(fineness) 1 / 2or d [μm] = 12 × (linear density) 1 / 2 Since it is represented by this, when the core yarn or the winding yarn is nylon or olefin, these formulas can be applied to the above formula instead of d [μm] = 10 × (linear density). 1 / 2 Even when the core yarn or the winding yarn is other than polyester, nylon, and olefin, since the relational expression between the linear density and the diameter d as described above is known (for example, described in Fiber Handbook edited by the Fiber Society, etc.), the relational expression may be applied to the above formula. As is clear from the figure on the right side of FIG. 1, the ratio of the length of the winding yarn 3 to the length of the core yarn 2 is represented by the following formula. Ratio of the length of the winding yarn to the length of the core yarn = (length of line segment A'B') / (length of line segment B'C) = 1 / sinθ1 Formula (2) From the above formulas (1) and (2), it is understood that the ratio of the length of the winding yarn to the length of the core yarn can be adjusted by the linear density of the core yarn, the linear density of the winding yarn, the covering number of the winding yarn, and / or the helix angle of the winding yarn.

[0020] In the left figure of FIG. 1, it is assumed that the core yarn 2 and the winding yarn 3 are in a non-deformed cylindrical shape, but in reality, usually, the core yarn 2 and the winding yarn 3 are deformed to some extent from the cylindrical shape. Also, in the central and right figures of FIG. 1, the diameter of the winding yarn 3 is not considered. However, it has been confirmed that tanθ or the yarn length ratio calculated using Formulas (1) and (2) agrees well with tanθ or the yarn length ratio actually measured from the manufactured covering yarn. Therefore, Formulas (1) and (2) can be used to obtain a desired yarn length ratio or to determine the covering number or helix angle of the winding yarn.

[0021] Generally, in order to exhibit the bulkiness of the yarn used, fabrics are often heat-treated after weaving or knitting (for example, at a temperature of 100 to 180 °C, for example, about 130 °C). When a fabric is woven or knitted using the covering yarn of the present invention, it is also preferable to perform a heat treatment at, for example, 130 °C for 3 minutes after weaving or knitting. Therefore, by obtaining the ratio of the length of the winding yarn to the length of the core yarn of the covering yarn after such heat treatment, it is possible to evaluate a ratio of the length of the winding yarn to the length of the core yarn that is closer to the ratio of the yarn lengths when actually manufacturing a plush fabric. This yarn length ratio after heat treatment can be obtained in the same manner as the method for obtaining the ratio of the length of the winding yarn to the length of the core yarn of the covering yarn described above, except that the measurement target is changed from the covering yarn to the covering yarn after heat treatment.

[0022] For example, the ratio of the length of at least the outermost winding yarn to the length of the core yarn of the covering yarn after heat treatment at 130 °C for 3 minutes is preferably 1.10 or more, more preferably 1.11 or more, still more preferably 1.20 or more, and particularly preferably 1.30 or more, from the viewpoints of a sufficient yarn length difference between the core yarn and the outermost winding yarn and the unwindability. The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn. From the viewpoint of ease of unwinding, the ratio is preferably 1.80 or less (for example, 1.70 or less or 1.60 or less).

[0023] When there are a plurality of winding yarns, such as in the case where the covering yarn is a double covering yarn, the ratio of the length of the inner winding yarn to the length of the core yarn of the covering yarn after heat treatment at 130 °C for 3 minutes may be preferably 1.02 or more (for example, 1.03 or more, 1.04 or more, or 1.05 or more). The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn. From the viewpoints of productivity and / or the appearance after unwinding, the ratio is preferably 2.90 or less (for example, 2.40 or less or 1.90 or less). The ratio of the length of the core yarn to the length of the inner winding yarn that is not unwound or for which unwinding is not intended of the covering yarn after heat treatment at 130 °C for 3 minutes can be equal to or greater than the lower limit value and equal to or less than the upper limit value. In one embodiment of the present invention, from the viewpoints of a sufficient yarn length difference and unwindability between the core yarn and the inner winding yarn, the ratio may preferably be 1.04 or more (for example, 1.05 or more, 1.06 or more, or 1.07 or more). The preferable upper limit value of the ratio varies depending on the configuration of the covering yarn. From the viewpoint of ease of unwinding, the ratio is preferably 1.70 or less (for example, 1.60 or less or 1.50 or less).

[0024] The ratio of the length of the winding yarn to the length of the core yarn of the covering yarn after heat treatment at 130°C for 3 minutes can be adjusted to be equal to or higher than the lower limit value and equal to or lower than the upper limit value by selecting the fineness of the core yarn, the fineness of the winding yarn, the heat shrinkage rate of the core yarn, the heat shrinkage rate of the winding yarn, the covering number of the winding yarn, and / or the helix angle of the winding yarn. In one embodiment of the present invention, by adjusting the ratio of the length of the winding yarn to the length of the core yarn of the covering yarn to be equal to or higher than the lower limit value and equal to or lower than the upper limit value described above, the ratio of the length of the winding yarn to the length of the core yarn of the covering yarn after heat treatment at 130°C for 3 minutes can be adjusted to be equal to or higher than the lower limit value and equal to or lower than the upper limit value. Also, by measuring in advance the heat shrinkage rates of the core yarn and the winding yarn before and after heat treatment under predetermined conditions, a covering yarn is used to produce and weave a pile fabric, and a standard value (covering number of the winding yarn) of the setting of the covering yarn manufacturing apparatus can be determined to obtain a desired ratio of the length of the winding yarn to the length of the core yarn after heat treatment under the predetermined conditions.

[0025] The diameter of the covering yarn greatly depends on the fineness of the core yarn, the fineness of the winding yarn, and the number of winding yarns. From the viewpoint of the standing property of the pile yarn, the diameter of the covering yarn is preferably 200 μm or more (for example, 220 μm or more, 240 μm or more, or 250 μm or more). The upper limit value of the diameter of the covering yarn is not particularly limited, but from the viewpoint of manufacturability in weaving, it is preferably 350 μm or less (for example, 330 μm or less, 310 μm or less, or 300 μm or less). The diameter of the covering yarn can be determined using a photograph of the covering yarn taken at an enlarged scale. For example, it can be determined by the method described in the examples below.

[0026] <Winding yarn> For all the wound yarns, the breaking strength of each wound yarn is 2 cN / dtex or more. If the breaking strength of the wound yarn is less than 2 cN / dtex, fibers will drop off from the wound yarn during the unwinding of the covering yarn or during the fibrillation when a raised fabric is manufactured using the covering yarn. From the perspective of suppressing such fiber drop-off, the breaking strength of the wound yarn is preferably 2.1 cN / dtex or more, more preferably 2.5 cN / dtex or more, still more preferably 3.0 cN / dtex or more, and particularly preferably 3.3 cN / dtex or more. The upper limit value of the breaking strength of the wound yarn is not particularly limited, but it is usually 7.0 cN / dtex or less. The breaking strength of the wound yarn can be measured according to JIS L 1013:2021, and more specifically, by the method described in the examples below.

[0027] For all the wound yarns, from the perspective of having a sufficient yarn length difference between the core yarn and the wound yarn, the fineness of each wound yarn is preferably 165 dtex or more, more preferably 200 dtex or more, still more preferably 250 dtex or more, and particularly preferably 300 dtex or more. The upper limit value of the fineness of the wound yarn is not particularly limited, but from the perspective of the productivity of the covering yarn, it is preferably 1000 dtex or less, more preferably 900 dtex or less, still more preferably 600 dtex or less, and particularly preferably 500 dtex or less. The fineness of the wound yarn can be measured according to JIS L 1013:2021, and more specifically, by the method described in the examples below.

[0028] At least the outermost winding yarn is a false-twist yarn or a composite yarn containing a false-twist yarn (hereinafter also referred to as a "false-twist yarn-containing composite yarn"). The false-twist yarn in this specification means a false-twist yarn commonly used in the art, that is, a processed yarn manufactured by the false-twist method. The false-twist yarn-containing composite yarn in this specification means a yarn in which such a false-twist yarn and a false-twist yarn or raw yarn are combined by fluid entanglement. Examples of such composite yarns include interlace yarns and taslan yarns. False-twist yarns range from non-bulky false-twist yarns with little bulkiness to highly crimped false-twist yarns with high bulkiness depending on the false-twist conditions. However, the false-twist yarn or false-twist yarn-containing composite yarn constituting at least the outermost winding yarn of the covering yarn of the present invention is not non-bulky and has a crimp elongation rate of 10% or more, preferably 12% or more, more preferably 15% or more, and particularly preferably 20% or more from the viewpoint of the unwindability of the outermost winding yarn and the volume of the yarn after unwinding the winding yarn. The upper limit value of the crimp elongation rate is not particularly limited, but from the viewpoint of workability when manufacturing the covering yarn, it is preferably 60% or less, more preferably 40% or less. The crimp elongation rate can be adjusted to be not less than the lower limit value and not more than the upper limit value by selecting the false-twist conditions. The crimp elongation rate can be measured by the method described in the examples below.

[0029] False-twist yarns include false-twist yarns having no torque or low torque or high-torque false-twist yarns depending on the setting of the number of false-twists in the false-twist method. Furthermore, there are also non-torque false-twist yarns that are substantially torque-free, which are manufactured by simultaneously winding two false-twist yarns with opposite twisting directions in twist-heat setting. However, the outermost winding yarn (false-twist yarn or false-twist yarn-containing composite yarn) in the covering yarn of the present invention has torque and is wound in the direction opposite to that torque. Here, being wound in the direction opposite to the torque of the winding yarn means that when the torque of the winding yarn is in the S direction, it is wound in the Z direction, and when the torque of the winding yarn is in the Z direction, it is wound in the S direction. With this configuration, the outermost winding yarn can be unwound as desired. On the other hand, if the outermost winding yarn has torque and is wound in the same direction as that torque, it is difficult to unwind the winding yarn as desired.

[0030] Further, the inventors have found that the greater the torque of the winding yarn wound in the direction opposite to its own torque, the more the covering number of the winding yarn can be set high while ensuring the unwinding property of the winding yarn. Since an increase in the covering number results in an increase in the ratio of the length of the winding yarn to the length of the core yarn, the greater the torque of the winding yarn wound in the direction opposite to its own torque, the greater the ratio of the length of the winding yarn to the length of the core yarn can be made while ensuring the unwinding property of the winding yarn. From this viewpoint, the false-twist yarn or the false-twist yarn-containing composite yarn as at least the outermost winding yarn preferably has a torque of 30 t / m or more, more preferably 50 t / m or more, still more preferably 60 t / m or more, and particularly preferably 80 t / m or more. The upper limit value of the torque is preferably 120 t / m or less, more preferably 110 t / m or less, and still more preferably 100 t / m or less from the viewpoints of suppressing the generation of snarls and handleability. The torque can be measured by the method described in the examples below.

[0031] When there are a plurality of winding yarns, the inner winding yarn is not particularly limited as long as its breaking strength is 2 cN / dtex or more. Examples of the types of yarns constituting the inner winding yarn include spun yarns, false-twist yarns, and false-twist yarn-containing composite yarns. Among these, from the viewpoint of the standing property of the cut pile yarn when the covering yarn of the present invention is used as the cut pile yarn of a plush fabric, a false-twist yarn or a false-twist yarn-containing composite yarn is preferable. The crimp elongation rate, the presence or absence of torque, the magnitude of torque, and the relationship between torque and the winding direction of the false-twist yarn or the false-twist yarn-containing composite yarn as the inner winding yarn are not particularly limited. From the viewpoint of the unwinding property of the inner winding yarn or from the viewpoint of a greater yarn length difference between the core yarn and the inner and outer winding yarns, the crimp elongation rate, the presence or absence of torque, the magnitude of torque, and the relationship between torque and the winding direction of the false-twist yarn or the false-twist yarn-containing composite yarn as the inner winding yarn can conform to the embodiments, particularly the preferred embodiments, of the crimp elongation rate, the presence or absence of torque, the magnitude of torque, and the relationship between torque and the winding direction of the false-twist yarn or the false-twist yarn-containing composite yarn as at least the outermost winding yarn described above.

[0032] In one embodiment of the present invention, all the winding yarns are false-twisted yarns or composite yarns containing false-twisted yarns. In this embodiment, the types and physical properties of each winding yarn may be the same or different. In the embodiment of at least the outermost winding yarn in this embodiment, the above-described embodiments of the outermost or at least the outermost winding yarn, particularly preferred embodiments, may be applicable. In the embodiment of the inner winding yarn when there are a plurality of winding yarns in this embodiment, the above-described embodiments of the inner winding yarn, particularly preferred embodiments, may be applicable.

[0033] Regarding the winding yarns other than the outermost winding yarn, when the false-twisted yarn or the composite yarn containing a false-twisted yarn constituting the winding yarn has torque, if the winding yarn is wound in the same direction as its own torque, it is difficult to unwind the winding yarn well. Therefore, a configuration intended not to unwind a specific winding yarn other than the outermost winding yarn can be achieved by winding the winding yarn in the same direction as its own torque. Regarding the winding yarns other than the outermost winding yarn, when the false-twisted yarn or the composite yarn containing a false-twisted yarn constituting the winding yarn has torque, if the winding yarn is wound in the opposite direction to its own torque, the winding yarn can be unwound as desired. Also, the greater the torque of the winding yarn wound in the opposite direction to its own torque, the unwindability of the winding yarn can be ensured even if the covering number of the winding yarn is set high. Since an increase in the covering number results in an increase in the ratio of the length of the winding yarn to the length of the core yarn, the greater the torque of the winding yarn wound in the opposite direction to its own torque, the ratio of the length of the winding yarn to the length of the core yarn can be increased while ensuring the unwindability of the winding yarn.

[0034] In one embodiment of the present invention, the covering yarn is a single covering yarn. In another embodiment of the present invention, the covering yarn is a double covering yarn.

[0035] In another embodiment of the present invention, the covering yarn is a double covering yarn, the inner winding yarn has torque, and is wound in a direction opposite to its own torque. With this configuration, in addition to the outer winding yarn, the inner winding yarn can also be unwound as desired. In another embodiment of the present invention, the covering yarn is a double covering yarn, the inner winding yarn has torque, and is wound in the same direction as its own torque. With this configuration, the outer winding yarn can be unwound as desired, and the inner winding yarn can be designed to be difficult to unwind as desired. In another embodiment of the present invention, the covering yarn is a double covering yarn, and the inner winding yarn and the outer winding yarn are wound in opposite directions. With this configuration, the covering yarn can be handled without fluff. This embodiment is particularly preferable in the case of a design intended to unwind both the outer winding yarn and the inner winding yarn, but also applies to the case of a design intended to unwind only the outer winding yarn and not the inner winding yarn. In another embodiment of the present invention, the covering yarn is a double covering yarn, and the inner winding yarn and the outer winding yarn are wound in the same direction. This embodiment is particularly preferable in the case of a design intended to unwind only the outer winding yarn and not the inner winding yarn, but also applies to the case of a design intended to unwind both the outer winding yarn and the inner winding yarn.

[0036] The descriptions of the torque and winding direction of the winding yarn up to this point generally present relationships suitable for the case where heating is not performed on the false-twisted yarn or the composite yarn containing false-twisted yarn (abbreviated as false-twisted yarn etc.) before dyeing or producing covering yarn. For example, when using a dyed false-twisted yarn etc. as the false-twisted yarn constituting the winding yarn of the covering yarn, the torque originally possessed by the false-twisted yarn etc. may be thermally fixed by the influence of heating during the dyeing process and may become substantially non-torque false-twisted yarn etc. When using such false-twisted yarn etc. for the covering yarn, it is preferable to twist (super-twist) the false-twisted yarn etc. alone to express torque again. In this case, the direction in which torque is expressed is opposite to the direction of twisting. That is, when twisted in the Z direction, S-direction torque is generated. In the present invention, when intending to unwind the winding yarn, it is preferable to wind in the direction opposite to the torque of the winding yarn. Therefore, when using a super-twisted dyed false-twisted yarn etc., winding in the same direction as the super-twist direction of the false-twisted yarn etc. makes it easier to unwind the winding yarn composed of the false-twisted yarn etc. Conversely, in the case of a winding yarn not intended to be unwound, it is preferable to wind in the direction opposite to the super-twist direction of the false-twisted yarn etc. Such a relationship is not limited to the case of dyed false-twisted yarn etc. For example, even in the case of raw silk that originally has no torque, the same effect (ease of unwinding) as described above can be obtained by twisting this alone and winding in the twisting direction.

[0037] In one embodiment of the present invention, regarding the winding yarn in the case where the covering yarn is a single covering yarn, or the inner winding yarn in the case where the covering yarn is a double covering yarn, the relationship among the fineness D1 of the core yarn, the fineness D2 of the winding yarn, and the covering number T1 of the winding yarn is given by the following formulas (I) to (III): When 330 dtex ≤ total fineness < 1000 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <12000 (I) When 1000 dtex ≤ total fineness < 1350 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <23500 (II) When 1350 dtex ≤ total fineness < 1760 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <30000 (III) [In formulas (I) to (III), the total fineness is D1 + D2, 165 dtex ≤ D1 ≤ 1100 dtex, and 165 dtex ≤ D2 ≤ 660 dtex.] It is represented by any one of . In this embodiment, when the covering yarn is a double covering yarn, the inner winding yarn is a false twist yarn or a composite yarn containing a false twist yarn, has torque, is wound in the opposite direction to the torque, and has a crimp elongation rate of 10% or more. The covering number of the winding yarn in this specification is a value measured with reference to "Measurement of More Number" described in C.10 of JIS L 1095:2010, more specifically, a value measured by the method described in the examples below.

[0038] The lower limit value in the above formula (I) is preferably 9100 or more (for example, 9200 or more or 9300 or more), and the upper limit value in the above formula (I) is preferably 11900 or less (for example, 11800 or less or 11700 or less). The lower limit value in the above formula (II) is preferably 9100 or more (for example, 9200 or more or 9300 or more), and the upper limit value in the above formula (II) is preferably 23400 or less (for example, 23300 or less or 23200 or less). The lower limit value in the above formula (III) is preferably 9100 or more (for example, 9200 or more or 9300 or more), and the upper limit value in the above formula (III) is preferably 29900 or less (for example, 29800 or less or 29700 or less). T1 × (total fineness) in formulas (I) to (III) 1 / 2 When it is equal to or greater than the lower limit value and equal to or less than the upper limit value, the winding yarn in the case of a single covering yarn or the inner winding yarn in the case of a double covering yarn can be unwound more favorably.

[0039] Conversely, when the covering yarn is a double covering yarn and it is intended that the inner winding yarn does not unwind, T1 × (total fineness) in formulas (I) to (III) 1 / 2 When it is less than the lower limit value or exceeds the upper limit value, the inner winding yarn can be designed not to unwind.

[0040] In one embodiment of the present invention, regarding the outer winding yarn when the covering yarn is a double covering yarn, the relationships among the fineness D1 of the core yarn, the fineness D2 of the inner winding yarn, the fineness D3 of the outer winding yarn, and the covering number T2 of the outer winding yarn are represented by the following formulas (IV) to (VII): When 495 dtex ≤ total fineness < 1100 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <18700 (IV) When 1100 dtex < total fineness < 1400 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <22000 (V) When 1400 dtex < total fineness < 1600 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <26000 (VI) When 1650 dtex < total fineness < 2420 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <28500 (VII) In formulas (IV) to (VII), the total fineness is D1 + D2 + D3, 165 dtex ≤ D1 ≤ 1100 dtex, 165 dtex ≤ D2 ≤ 660 dtex, and 165 dtex ≤ D3 ≤ 660 dtex. It is represented by any one of them.

[0041] The lower limit value in the above formula (IV) is preferably 8500 or more (for example, 8600 or more or 8700 or more), and the upper limit value in the above formula (IV) is preferably 17900 or less (for example, 17800 or less or 17700 or less). The lower limit value in the above formula (V) is preferably 8500 or more (for example, 8600 or more or 8700 or more), and the upper limit value in the above formula (V) is preferably 21900 or less (for example, 21800 or less or 21700 or less). The lower limit value in the above formula (VI) is preferably 8500 or more (for example, 8600 or more or 8700 or more), and the upper limit value in the above formula (VI) is preferably 25900 or less (for example, 25800 or less or 25700 or less). The lower limit in the above formula (VII) is preferably 8500 or more (for example, 8600 or more or 8700 or more), and the upper limit in the above formula (VII) is preferably 28400 or less (for example, 28300 or less or 28200 or less). T2 × (total fineness) in formulas (IV) to (VII) 1 / 2 When it is not less than the lower limit and not more than the upper limit, the outer winding yarn in the case of a double covering yarn can be more favorably unwound.

[0042] The preferred helix angle of the winding yarn varies depending on the structure of the covering yarn. The helix angle of the covering yarn can be determined using a photograph of the covering yarn taken at an enlarged scale. For example, it can be determined by the method described in the examples below.

[0043] Alternatively, it can be obtained using the diameter of the covering yarn and the distance between adjacent winding yarns. A specific method of obtaining will be described with reference to FIGS. 2 and 3. FIG. 2 is an image taken at a magnification of 100 times with a magnifying glass (model number VHX-5000, manufactured by Keyence Corporation) of 11 arbitrarily selected adjacent covering yarns after winding the covering yarns of an embodiment of the present invention onto cardboard little by little so that the covering yarns do not overlap and applying a tensile tension of 2 cN or more. First, in the image of each covering yarn, a representative zigzag line 4 is drawn, the distance d1 is measured at 5 locations (only 1 location is shown in FIG. 2 for easy viewing), and their average value is obtained to obtain the diameter (μm) of the covering yarn. Next, the average value of the 11 diameters is obtained to obtain the diameter (μm) of the covering yarn to be measured. Next, 7 straight lines 5 (dashed lines) are drawn along the winding yarn, and the distance 6 (corresponding to the distance of the winding yarn) (μm) between adjacent straight lines 5 is measured (only 1 location is shown in FIG. 2 for easy viewing). Their average value is obtained to obtain the distance (μm) of the winding yarn in the covering yarn. Next, the average value of the 11 distances is obtained to obtain the distance (μm) of the winding yarn in the covering yarn to be measured. In FIG. 2, for easy viewing, auxiliary lines (such as straight lines 4 to 6) for one covering yarn are shown, but actually, for each of the 11 covering yarns, auxiliary lines are similarly drawn to obtain the diameter of the covering yarn and the distance between adjacent winding yarns. The arrangement of the core yarn and the winding yarn in the covering yarn can be represented by a schematic diagram showing that a parallelogram paper (winding yarn) is wound around a cylindrical object (core yarn) at a helix angle θ3 (radians) (see FIG. 3). In FIG. 3, D and E are the vertices of the parallelogram paper, F is the intersection of the straight line drawn from vertex E to the side of the parallelogram paper and the side when the angle DFE is a right angle, and G is the intersection of the straight line drawn from vertex E to the side of the parallelogram paper and the side when the angle DEG is a right angle. As is clear from FIG. 3, since θ3’ corresponds to the helix angle θ3, sinθ3 is represented by the following formula. sinθ3 = (length of line segment EF) / (length of line segment EG) Here, since the length of line segment EG is equal to π × (diameter d2 of the covering yarn), sinθ3 = (length of line segment EF) / (πd2) By substituting the distance between adjacent winding yarns obtained from Figure 2 as the length of line segment EF and the diameter of the covering yarn obtained from Figure 2 as d2, the helix angle θ3 can be determined.

[0044] The polymer constituting the winding yarn is not particularly limited. Examples of the polymer include aromatic polyesters such as polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate, aliphatic polyesters such as polylactic acid and polyglycolic acid, polyesters copolymerized with a third component (e.g., isophthalic acid and / or 5-sodium sulfoisophthalic acid) of these polyesters, polymers kneaded with a functional agent (e.g., deodorant and / or flame retardant) of these polyesters, aliphatic polyamides such as nylon 6, nylon 66, and nylon 610, polyolefins such as polystyrene, polyvinyl chloride, and polyvinylidene chloride, and acrylic or acrylic-based polymers. The winding yarn may be composed of one kind of polymer or two or more kinds of polymers, and may be, for example, a core-sheath type, a segmented type, or a sea-island type. Among the polymers exemplified above, from the viewpoint of the crimp manifestation property after false twisting, polyethylene terephthalate, nylon 66, and polystyrene are preferable, and polyethylene terephthalate and nylon 66 are more preferable. The cross-sectional shape of the winding yarn is not particularly limited, and may be, for example, a round cross-section, flat, multi-filament shape, or a mix of irregular cross-sections. The single-filament fineness of the winding yarn is preferably 0.05 dtex or more and 60 dtex or less.

[0045] <Core yarn> The breaking strength of the core yarn is 2 cN / dtex or more. If the breaking strength of the core yarn is less than 2 cN / dtex, fibers will drop off from the core yarn during the unwinding of the covering yarn or during the fiber opening when a pile fabric is manufactured using the covering yarn. From the perspective of suppressing such fiber drop-off, the breaking strength of the core yarn is preferably 2.1 cN / dtex or more, more preferably 2.5 cN / dtex or more, still more preferably 2.7 cN / dtex or more. The upper limit value of the breaking strength of the core yarn is not particularly limited, but is usually 7.0 cN / dtex or less. The breaking strength of the core yarn can be measured according to JIS L 1013:2021, and more specifically, by the method described in the examples below.

[0046] From the perspective of a greater difference in yarn length between the core yarn and the winding yarn and the unwinding property of the winding yarn, the fineness of the core yarn is preferably 165 dtex or more, more preferably 200 dtex or more, still more preferably 300 dtex or more, and particularly preferably 400 dtex or more. The upper limit value of the fineness of the core yarn is not particularly limited, but from the perspective of the productivity of the covering yarn, it is preferably 1500 dtex or less, more preferably 1200 dtex or less, still more preferably 800 dtex or less, and particularly preferably 600 dtex or less. The fineness of the core yarn can be measured according to JIS L 1013:2021, and more specifically, by the method described in the examples below. Regarding the unwinding property of the winding yarn, it has been found that when the fineness of the winding yarn is fixed, the higher the fineness of the core yarn, the more the covering number of the winding yarn can be ensured even when set high. That is, the difference between the length of the core yarn and the length of the winding yarn can be increased. On the other hand, when the fineness of the core yarn is fixed, it has been found that the higher the fineness of the winding yarn, the more the unwinding property of the winding yarn can be ensured even when the covering number is set high.

[0047] The type of yarn constituting the core yarn is not particularly limited as long as the breaking strength of the core yarn is 2 cN / dtex or more. Examples of the type of yarn constituting the core yarn include spun yarn, false-twist yarn, and false-twist yarn-containing composite yarn. Among these, from the perspective of the standing property of the cut pile yarn when the covering yarn of the present invention is used as the cut pile yarn of a pile fabric, false-twist yarn or false-twist yarn-containing composite yarn is preferred.

[0048] The crimp elongation rate, presence or absence of torque, and magnitude of torque of the false-twisted yarn or false-twisted yarn-containing composite yarn as the core yarn are not particularly limited. From the viewpoint of the larger difference between the length of the core yarn and the length of the wrapping yarn, the crimp elongation rate of the false-twisted yarn or false-twisted yarn-containing composite yarn as the core yarn is preferably 10% or more, more preferably 15% or more, still more preferably 20% or more. From the viewpoint of workability in manufacturing the covering yarn, it is preferably 60% or less, more preferably 40% or less, still more preferably 30% or less. The crimp elongation rate can be adjusted to be not less than the lower limit value and not more than the upper limit value by selecting the false-twisting conditions. The crimp elongation rate of the core yarn can be measured by the method described in the examples below. From the viewpoint of suppressing the generation of fluff, the false-twisted yarn or false-twisted yarn-containing composite yarn as the core yarn preferably has a torque of 20 t / m or less, more preferably 10 t / m or less, still more preferably 7 t / m or less, or preferably has no torque. The torque can be measured by the method described in the examples below.

[0049] The polymer constituting the core yarn is not particularly limited. The type of the polymer constituting the core yarn, as well as the constitution, cross-sectional shape, and single-filament fineness of the core yarn, etc. may be the same as those of the wrapping yarn.

[0050] [Method for manufacturing covering yarn] The covering yarn of the present invention can be manufactured by a method known in the art using a manufacturing apparatus known in the art as schematically shown in FIG. 4, for example. As an example of such a method, in the case of a single covering yarn, the core yarn sent out from the core yarn cheese is passed through a hollow spindle, and the wrapping yarn is wound around the core yarn at a predetermined covering number by rotating the wrapping yarn bobbin installed on the hollow spindle, and the obtained covering yarn is wound up. As an example of the manufacturing method in the case of winding a plurality of wrapping yarns, an example of the manufacturing method in the case of a single covering yarn described above can be mentioned except that there are a plurality of wrapping yarn bobbins installed on the hollow spindle and the wrapping yarns are sequentially wound around the core yarn at a predetermined covering number by rotating them.

[0051] As described above, the covering number of the winding yarn can be calculated by inputting the ratio of the length of the winding yarn to the length of the desired core yarn into Equation (2) to obtain the spiral angle of the winding yarn, and then inputting the obtained spiral angle and the fineness of the core yarn and the winding yarn used into Equation (1). By setting the calculated covering number in the manufacturing apparatus and optionally finely adjusting the covering number as necessary, a covering yarn having a ratio of the length of the winding yarn to the length of the desired core yarn can be manufactured. The above-described fine adjustment of the covering number is necessary when there is a difference between the set covering number and the actually measured covering number. For example, when the actually measured covering number is slightly smaller than the set covering number, the set covering number may be slightly increased in order to obtain the desired yarn length ratio.

[0052] [Pile fabric] Using the covering yarn of the present invention, a pile fabric can be manufactured. Accordingly, the present invention also encompasses the above-described covering yarn for manufacturing a pile fabric (more specifically, a cut pile pile fabric). Since the covering yarn of the present invention exhibits a sufficient yarn length difference of two or more stages after the unwinding of the winding yarn, as described above, after the opening process that is usually performed in the finishing process of the pile fabric, a cut pile yarn length that is sufficiently longer than before the opening process can be achieved. Further, the yarn length of the cut pile yarn can be easily changed by changing the covering yarn used without changing the settings of the pile fabric manufacturing apparatus, and a long pile pile fabric can be manufactured using a general pile fabric manufacturing apparatus without accompanying a decrease in productivity without using a dedicated manufacturing apparatus. Furthermore, a uniform yarn length difference in the pile fabric can be achieved. The pile fabric can be manufactured using a general manufacturing apparatus. Examples of such manufacturing apparatuses include sinker pile knitting machines, seal fly knitting machines, double billow looms, tricot knitting machines, raschel knitting machines, and tufting machines. [Examples]

[0053] Hereinafter, the present invention will be specifically described by way of examples, but the scope of the present invention is not limited by these examples. In addition, the measurement methods of the physical properties of the core yarn, the winding yarn, and the covering yarn are described below. The physical properties and measurements (or physical property values and measurement values) described in this specification, including the examples, are based on the values obtained by the following methods.

[0054] <Breaking strength> For the core yarn and the winding yarn, in accordance with JIS L 1013:2021, the breaking strength was determined under the conditions of a sample length of 20 cm, an initial load of 0.1 g / d, and a tensile speed of 10 cm / min. It was measured with n = 5, and the average value was taken as the breaking strength of the yarn.

[0055] <Crimp elongation rate> Using a cassette winder, the sample was wound until it became a cassette of 5000 denier (d). The upper part of the wound sample was fixed, a 10 g load was applied so that a load of 0.001 g / d was applied to the wound sample, and the sample was immersed in hot water at 90 °C for 30 minutes with the load applied. The sample was taken out of the hot water and dried by leaving it in an environment of room temperature 20 °C ± 2 °C and relative humidity 65 ± 4% for one day and night in a load-free state. In the above environment, a 10 g load was applied to the sample again in the same manner, and after leaving it for 5 minutes, the yarn length (L0 [mm]) was measured with the load applied. Then, in the above environment, a 1.0 kg load was applied to the sample so that a load of 0.0001 g / d was applied, and after leaving it for 30 seconds, the yarn length (L1 [mm]) was measured with the load applied. The crimp elongation rate K1 was determined by the following formula. It was measured with n = 5 to obtain the crimp elongation rate, and the average value was taken as the crimp elongation rate of the sample. K1 [%] = {(L1 - L0) / L1} × 100

[0056] <Denier> For the core yarn and the winding yarn, the denier was measured in accordance with JIS L 1013:2021. It was measured with n = 5, and the average value was taken as the denier of the yarn.

[0057] <Torque> Torque was generated by hanging a 1 g weight at the center of a 1 m long sample and suspending it vertically, and the number of twists per 50 cm was measured. The value obtained by converting this number of twists to the number of twists per 1 m was taken as the torque of the sample. The direction of the torque was defined as the Z direction when the rotational direction of the weight was clockwise when observed from above, and the S direction when it was counterclockwise. For example, when the torque direction is the Z direction and the number of twists per 1 m is 10 t / m, the torque is expressed as Z10 t / m.

[0058] <Thermal shrinkage rate (Dsr)> A covering yarn (sample) that had been left standing for 24 hours in an environment of room temperature 20°C ± 2°C and relative humidity 65 ± 4% was wound 10 times around a bobbin winder with a circumference of 1 m, and then the length was measured under a load of 0.001 g / dtex, and this was designated as L0 [mm]. The sample was placed in a hot air circulation dryer set at 130°C in a no-load state and heat-treated for 3 minutes. After the heat treatment, the sample was taken out and allowed to cool to room temperature. Next, the length was measured under a load of 0.001 g / dtex, and this was designated as L1 [mm]. The thermal shrinkage rate (Dsr) of the covering yarn was determined by the following formula. Dsr [%] = {(L0 - L1) / L0} × 100 When manufacturing a fabric from yarn, heat treatment is often carried out after weaving or knitting. In one embodiment of the present invention, when a fabric is woven or knitted using a covering yarn, it is preferable to perform heat treatment at a temperature of about 130°C after weaving or knitting. Therefore, here, the thermal shrinkage rate when the covering yarn was heat-treated at 130°C was determined.

[0059] <Diameter of the covering yarn and helix angle of the winding yarn> The covering yarn to be measured was wound around cardboard so that a tensile tension of 2 cN or more was not applied. At this time, it was wound little by little while shifting so that the covering yarns did not overlap each other. Eleven arbitrarily selected adjacent covering yarns were photographed at a magnification of 100 times with a magnifying glass manufactured by KEYENCE CORPORATION (model number VHX-5000). An example of the photographed image is shown in Figure 2. In Figure 2, for easy viewing, the diameter of one covering yarn and auxiliary lines (such as straight line 4) for obtaining the helix angle of the wound yarn are shown, but actually, for each of the 11 covering yarns, auxiliary lines were drawn in the same way to obtain the diameter of the covering yarn and the helix angle of the wound yarn. In the image of each covering yarn, a representative zigzag line 4 was drawn, and the distance d1 was measured at 5 locations (only one location is shown in Figure 2 for easy viewing). The average value of them was obtained and used as the diameter of each covering yarn. The average value of the 11 diameters was obtained and used as the diameter of the covering yarn to be measured. Next, the helix angle of the wound yarn was obtained from the image of each covering yarn. Specifically, seven straight lines 5 (dashed lines) were drawn along the wound yarn, and the angle φ between each straight line 5 and the zigzag line 4 was measured (only one location is shown in Figure 2 for easy viewing), and the average value of them was obtained. The value obtained by subtracting the angle φ from 90° was used as the helix angle of each covering yarn. The average value of the 11 helix angles was obtained and used as the helix angle θ2 (°) of the wound yarn of the covering yarn to be measured.

[0060] <Covering number of the wound yarn> Measurement was made with reference to "Measurement of More Numbers" described in C.10 of JIS L 1095:2010. Set the gripping interval of the untwisting machine to 250 mm ± 0.5 mm (i.e., this interval becomes the sample length), and set the covering yarn (sample) to be measured. When the core yarn of the covering yarn is untwisted, as the untwisting progresses, the core yarn is twisted, and as a result, the entire covering yarn begins to shrink. To enable measurement even when it shrinks, one of the non-rotating gripping parts can be moved in the longitudinal direction of the sample. Also, when the covering yarn is a double covering yarn, after measuring the covering number of the outer winding yarn, turn the tachometer in the opposite direction to return it to the original position, and then measure the covering number of the inner winding yarn in the same manner as the covering number of the outer winding yarn. The number of measurements was set to 5 times, the average value was calculated, and by converting it to the number of rotations per 1 meter, the covering number of the winding yarn was determined. For example, when the winding direction is the Z direction and the number of rotations per 1 m is 10 t / m, the covering number is expressed as Z10 t / m. Also, calculate the product of the measured covering number and the value obtained by taking the square root of the total fineness of the covering yarn, and check whether the product satisfies any of the following formulas (I) to (VII). For the winding yarn when the covering yarn is a single covering yarn, or for the inner winding yarn when the covering yarn is a double covering yarn: When 330 dtex ≤ total fineness < 1000 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <12000 (I) When 1000 dtex ≤ total fineness < 1350 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <23500 (II) When 1350 dtex ≤ total fineness < 1760 dtex, 9000 ≤ T1 × (total fineness) 1 / 2 <30000 (III) [In formulas (I) to (III), the total fineness is the fineness D1 of the core yarn + the fineness D2 of the winding yarn, 165 dtex ≤ D1 ≤ 1100 dtex, 165 dtex ≤ D2 ≤ 660 dtex, and T1 is the covering number of the winding yarn in the case of a single covering yarn or the covering number of the inner winding yarn in the case of a double covering yarn] For the outer winding yarn when the covering yarn is a double covering yarn: When 495 dtex ≤ total fineness < 1100 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <18700 (IV) When 1100 dtex < total fineness < 1400 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <22000 (V) When 1400 dtex < total fineness < 1600 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <26000 (VI) When 1650 dtex < total fineness < 2420 dtex, 8400 ≤ T2 × (total fineness) 1 / 2 <28500 (VII) [In formulas (IV) to (VII), the total fineness is the fineness D1 of the core yarn + the fineness D2 of the inner wrapping yarn + the fineness D3 of the outer wrapping yarn, 165 dtex ≤ D1 ≤ 1100 dtex, 165 dtex ≤ D2 ≤ 660 dtex, 165 dtex ≤ D3 ≤ 660 dtex, and T2 is the covering number of the outer wrapping yarn]

[0061] <Ratio of the length of the wrapping yarn to the length of the core yarn> The covering yarn to be measured was placed on cardboard, and both ends of the sample were fixed to the cardboard using cellophane tape so that a tensile tension of 2 cN or more was not applied and the sample length was 200 mm. Then, using a cutter, the sample was cut at the boundary between one cellophane tape and the sample, and one end of the sample was made into a free end. The free end was pinched, and the wrapping yarn was carefully unwound (in the order of the outer wrapping yarn when there are multiple wrapping yarns) so that a tensile tension of 2 cN or more was not applied. For each of the wrapping yarn and the core yarn, with a tensile tension of 2 cN applied, the yarn length was measured using a scale with a minimum scale of 1 mm. The number of measurements was 5 times, and the average value was taken as the yarn length of each yarn. Then, the ratio of the length of the wrapping yarn to the length of the core yarn was calculated. The test was conducted under an environment of room temperature 20°C ± 2°C and relative humidity 65 ± 4%. As described above, in one embodiment of the present invention, when a fabric is knitted or woven using a covering yarn, it is preferable to perform a heat treatment at a temperature of about 130°C after knitting or weaving. By obtaining the ratio of the length of the winding yarn to the length of the core yarn of the covering yarn after the heat treatment at 130°C, it is possible to evaluate the ratio of the length of the winding yarn to the length of the core yarn, which is closer to the ratio of the yarn lengths when actually manufacturing a pile fabric. Therefore, for the covering yarn heat-treated for 3 minutes in a hot air circulation dryer set at 130°C, the ratio of the length of the winding yarn to the length of the core yarn was calculated in the same manner as described above.

[0062] <Spinning performance of the winding yarn> Test pieces for evaluating the spinning performance of the winding yarn were prepared according to the following procedure. FIG. 5 shows a photograph of a test piece for evaluating the spinning performance of the winding yarn of a covering yarn according to one embodiment of the present invention. The photograph on the right side of FIG. 5 is a photograph taken by rotating the test piece in the photograph on the left side of FIG. 5 by 90°. A 50 mm × 45 mm 5 mm square grid paper was cut out and folded so that the length of the side in the longitudinal direction (the 50 mm side) became half (25 mm). A cardboard (thickness: 0.5 mm) of 25 mm × 45 mm was inserted between the folded square grid papers so that the square grid paper would not deform when the covering yarn was wound. The covering yarn was wound 11 times so that the 25 mm side and the covering yarn were generally parallel and did not overlap each other, and then the covering yarn in the range of 15 mm from the folded portion (both sides) was fixed with cellophane tape. Next, a cutter was inserted between one square grid paper and the cardboard, and the covering yarn was cut along the opposite side of the folded portion. By folding the region (10 mm × 45 mm) of one square grid paper where the covering yarn was not fixed in the direction where the covering yarn was not fixed, a test piece for evaluating the spinning performance of the winding yarn was obtained. As understood from FIG. 2, on one side of this test piece, 15 mm from one end of 11 covering yarns arranged in one direction was fixed, and 10 mm from the other end was not fixed. The spinning performance of the covering yarn in this unfixed portion was evaluated according to the following procedure. From the fixed base of the covering yarn towards the unfixed end, a raised card clothing (RS-2 manufactured by Kanai Juyo Kogyo Co., Ltd.) with a length of 5 cm and a base cloth width of 26 mm was brushed a predetermined number of times. At this time, a 500 g weight was fixed on the raised card clothing, and the raised card clothing was horizontally pulled and slid in the yarn length direction of the covering yarn at a speed of 20 cm / second for brushing. The unwindability of the wound yarn was visually evaluated according to the following criteria. A: All the wound yarns were unwound within 50 or fewer brushings. B: All the wound yarns were unwound within more than 50 and 75 or fewer brushings. C: Even within more than 75 brushings, at least a part of the wound yarns was not unwound.

[0063] [Example 1] As the core yarn, a false-twisted yarn A having the characteristics described in Table 1 was prepared. As the inner wound yarn, a composite yarn B having the characteristics described in Table 1 and including the false-twisted yarn was prepared. As the outer wound yarn, a composite yarn C having the characteristics described in Table 1 and including the false-twisted yarn was prepared. Next, each yarn was installed in a covering yarn manufacturing apparatus, the conditions of the manufacturing apparatus were set so that the covering number described in Table 3 was obtained, the inner wound yarn and the outer wound yarn were wound around the core yarn, and a covering yarn was manufactured. Then, the manufactured covering yarn was evaluated.

[0064] [Examples 2 to 4 and Comparative Examples 1 to 6] The type of the core yarn and / or the wound yarn was changed as described in Table 2, and a covering yarn was manufactured and evaluated in the same manner as in Example 1 except that the covering number was made as described in Table 3. Comparative Example 1 is an example in which a yarn having torque was wound in the same direction as the torque as the outer wound yarn. Comparative Example 2 is an example in which the crimp elongation rate of the outer wound yarn is less than 10%. Comparative Examples 3 and 6 are examples in which the ratio of the length of the outer wound yarn to the length of the core yarn is less than 1.20. Comparative Example 4 is an example in which the breaking strength of the core yarn is less than 2 cN / dtex. As is clear from the description in Table 2 or Table 3, a single covering yarn was manufactured in Example 3, and a double covering yarn was manufactured in the other examples. In Comparative Example 4, the wrap yarn used as the core yarn was produced by winding a polyester monofilament with a fineness of 33 dtex around an untwisted sliver made of rayon raw cotton with a fineness of 2.2 dtex and an average length of 51 mm at 200 t / m in the Z direction. The obtained wrap yarn had a cotton count of 5 (fineness: 1158.8 dtex), and the blending ratio was 97.2% rayon / 2.8% polyester.

[0065]

Table 1

[0066]

Table 2

[0067]

Table 3

[0068] In all of the examples of the present invention, a covering yarn for unwinding and using a wrap yarn that exhibits a sufficient yarn length difference of two or more stages after unwinding the wrap yarn was provided. In Example 2, by winding the inner wrap yarn in the same direction as its own torque, as intended, only the outer wrap yarn was unwound well.

[0069] On the other hand, in all of the comparative examples, no covering yarn was provided for unwinding and using a winding yarn that exhibits a sufficient yarn length difference of two or more stages after unwinding the winding yarn. In Comparative Example 4, although the unwindability of both the outer winding yarn and the inner winding yarn was evaluated as A, due to the core yarn being a wrap yarn with a breaking strength of 2 cN / dtex or less, the shedding of short fibers was severe, the sample after unwinding had a large amount of loose hairs, and it was not possible to measure the ratio of the length of the winding yarn to the length of the core yarn. Also, although the sample after unwinding had relatively long fibers and relatively short fibers, the variation in their lengths was large. In Comparative Example 5, an attempt was made to unwind the outer winding yarn in order to measure the ratio of the length of the winding yarn to the length of the core yarn, but it was not possible to unwind the outer winding yarn without applying a tensile tension of 2 cN or more, and it was not possible to measure the ratio of the length of the winding yarn to the length of the core yarn.

Industrial Applicability

[0070] The covering yarn of the present invention can exhibit a sufficient yarn length difference of two or more stages after unwinding the winding yarn. Further, the covering yarn of the present invention has sufficient handleability in the weaving process or knitting process, and fabric products such as woven fabrics, knitted fabrics, or unidirectional sheets (UD) can be manufactured using the covering yarn, and a part of the covering yarn in the manufactured fabric product can also be unwound. Therefore, the covering yarn of the present invention can be suitably used, for example, for manufacturing pile fabrics (e.g., pile fabrics for clothing), carpets, cleaning tools, or skin materials.

Explanation of Signs

[0071] 1 Single covering yarn 2 Core yarn 3 Winding yarn A End of the winding yarn in a state wound around the core yarn B End of the winding yarn in a state wound around the core yarn A’ End of the winding yarn before being wound around the core yarn B’ End of the winding yarn before being wound around the core yarn C The other vertex of a right triangle with the line segment A’B’ as the hypotenuse θ1 Helix angle of the winding yarn 4 Representative twill lines 5 Straight line drawn along the wound yarn 6 Distance between two adjacent straight lines 5 d1 Distance of the representative twill line (diameter of the covering yarn) φ Angle between the representative twill line 4 and the straight line 5 θ2 Helix angle of the wound yarn D Vertex of the parallelogram paper E Vertex of the parallelogram paper F Intersection point of the straight line drawn from the vertex E to the side of the parallelogram paper and the side when the angle DFE is a right angle G Intersection point of the straight line drawn from the vertex E to the side of the parallelogram paper and the side when the angle DEG is a right angle θ3 Helix angle of the wound yarn θ3’ Angle corresponding to the helix angle θ3 of the wound yarn DE Length corresponding to the distance between D and E EF Length corresponding to the distance between E and F 7 Double covering yarn 8 Core yarn 9 Inner wound yarn 10 Outer wound yarn 11 Covering yarn manufacturing device 12 Core yarn cheese 13 Hollow spindle for inner wound yarn 14 Hollow spindle belt for inner wound yarn 15 Bobbin for inner wound yarn 16 Balloon guide for inner wound yarn 17 Hollow spindle for outer wound yarn 18 Hollow spindle belt for outer wound yarn 19 Bobbin for outer wound yarn 20 Balloon guide for outer wound yarn 21 Covering yarn package 22 Roller 23 Guide 24 Sample before unwinding 25 Sample after unwinding

Claims

1. A covering yarn comprising a core yarn and one or more winding yarns wound around the periphery thereof, wherein the breaking strength of the core yarn and the winding yarns is 2 cN / dtex or more, at least the outermost winding yarn is a false-twist yarn or a composite yarn comprising a false-twist yarn, the ratio of the length of at least the outermost winding yarn to the length of the core yarn is 1.20 to 2.00, the outermost winding yarn has torque and is wound in the direction opposite to the torque, and the crimp elongation rate of at least the outermost winding yarn is 10% or more. A covering yarn for unwinding and using the winding yarn.

2. The covering yarn according to claim 1, wherein the fineness of the core yarn is 165 dtex or more.

3. The covering yarn according to claim 1, wherein the fineness of the winding yarn is 165 dtex or more.

4. The covering yarn according to claim 1, wherein the covering yarn is a single covering yarn.

5. The covering yarn according to claim 1, wherein the covering yarn is a double covering yarn, and the inner winding yarn has torque and is wound in the direction opposite to its own torque.

6. The covering yarn according to claim 1, wherein the covering yarn is a double covering yarn, and the inner winding yarn has torque and is wound in the same direction as its own torque.

7. The covering yarn according to claim 1, wherein all the winding yarns are false-twist yarns or composite yarns comprising false-twist yarns.

8. The covering yarn according to claim 5 or 6, wherein the inner winding yarn and the outer winding yarn are wound in opposite directions.

9. Regarding the winding yarn when the covering yarn is a single covering yarn, or the inner winding yarn when the covering yarn is a double covering yarn, the fineness D of the core yarn １ , the fineness D of the winding yarn ２ , and the covering number T of the winding yarn １ The relationship is given by the following formulas (I) to (III): When 330 dtex ≤ total fineness < 1000 dtex, 9000 ≤ T 1 × (total fineness) 1 / 2 < 12000 (I) When 1000 dtex ≤ total fineness < 1350 dtex, 9000 ≤ T 1 × (total fineness) 1 / 2 < 23500 (II) When 1350 dtex ≤ total fineness < 1760 dtex, 9000 ≤ T 1 × (total fineness) 1 / 2 < 30000 (III) In formulae (I) to (III), the total fineness is D 1 + D 2 where 165 dtex ≤ D 1 ≤ 1100 dtex, and 165 dtex ≤ D 2 ≤ 660 dtex) The covering yarn according to claim 1, represented by any of...

10. Regarding the outer winding yarn in the case where the covering yarn is a double covering yarn, the fineness D of the core yarn １ , the fineness D of the inner winding yarn ２ , the fineness D of the outer winding yarn ３ , and the covering number T of the outer winding yarn ２ The relationship is given by the following formulas (IV) to (VII): When 495 dtex ≤ total fineness < 1100 dtex, 8400 ≤ T 2 × (total fineness) 1 / 2 < 18700 (IV) When 1100 dtex < total fineness < 1400 dtex, 8400 ≤ T 2 × (total fineness) 1 / 2 < 22000 (V) When 1400 dtex < total fineness < 1600 dtex, 8400 ≦ T 2 × (total fineness) 1 / 2 <26000 (VI) When 1650 dtex < total fineness < 2420 dtex, 8400 ≤ T 2 × (total fineness) 1 / 2 < 28500 (VII) In formulas (IV) to (VII), the total fineness is D 1 + D 2 + D 3 where 165 dtex ≤ D 1 ≤ 1100 dtex, 165 dtex ≤ D 2 ≤ 660 dtex, 165 dtex ≤ D 3 ≤ 660 dtex] The covering yarn according to claim 1, represented by any of...

11. The covering yarn according to claim 1 for manufacturing a pile fabric.

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