Napped fabric and manufacturing method thereof

Abstract

To provide a napped fabric having two or more stages of different napped lengths uniformly in the entire target range of the fabric without being restricted by a manufacturing machine to be used and / or the setting conditions thereof.SOLUTION: A napped fabric comprises a ground weave part, and a napped part composed of a plurality of cut pile yarns constrained and erected by the ground weave part. The napped part includes a plurality of two or more types of cut pile yarns having different nap lengths, the cut pile yarns being derived from one covering yarn at least partially unwound and erected from the same root. At least a cut pile yarn having the longest nap length among the two or more types of cut pile yarns having different nap lengths is a false-twisted yarn or a composite yarn including a false-twisted yarn. A ratio of the nap length of the longest cut pile yarn to the nap length of the shortest cut pile yarn among the two or more types of cut pile yarns erected from the same root is 1.10 to 1.90.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a pile fabric, particularly a pile fabric composed of two or more kinds of cut pile yarns having different pile lengths derived from a covering yarn that has been opened, and a method for manufacturing the same.

Background Art

[0002] Conventionally, pile fabrics have been widely used in various applications such as cleaning wipes, clothing, and carpets. Pile fabrics can be manufactured from various fibers according to their applications using knitting and weaving machines such as sinker pile knitting machines, double velour looms, and tufting machines. The pile length of the pile fabric manufactured using such machines is generally determined by the components provided in the machines used (such as sinkers, loopers, etc.) and the conditions set in these machines (for example, Patent Documents 1 and 2).

[0003] On the other hand, in recent years, from the viewpoints of improving the functionality and design of pile fabrics, means for obtaining fabrics having different pile lengths without being restricted by the conditions in manufacturing machines have been desired, and various methods have been proposed. For example, Patent Document 3 discloses a two-stage cut pile product characterized in that a covering yarn obtained by overfeeding a yarn strip at least one of which is untwisted is used as a pile yarn, tufted to form a cut pile, and then subjected to an opening treatment to create a difference in yarn length with two or more kinds of yarn strips. Further, Patent Documents 4 to 6 disclose methods for providing a difference in pile length by utilizing the difference in shrinkage of fibers with respect to heat or solvents.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

[0005] In the conventional method of controlling the pile length of a pile fabric according to a manufacturing machine or its setting conditions, it is necessary to change the machine or its condition settings every time a different pile length is required. In particular, since special machines are required for manufacturing fabrics with a long pile length, a means for easily manufacturing fabrics having a plurality of different pile lengths regardless of the machine and its settings is desired.

[0006] As a method of manufacturing a fabric having different pile lengths regardless of the machine settings, in the cut pile product disclosed in Patent Document 3 above, short fibers are scraped out from the yarn of the untwisted yarn constituting the covering yarn, and the pile tips are stretched to create a two-step height difference. However, in such a method, it is difficult to form a high-density pile portion because a considerable amount of short fibers fall off during the fibrillation process. In addition, it is difficult to control the pile length to a desired length, and the variation in the pile length becomes large, resulting in problems such as poor texture and appearance. Furthermore, even when a yarn length difference is provided by utilizing the difference in fiber shrinkage with respect to heat or a solvent as disclosed in Patent Documents 4 to 6 above, a pile length exceeding the maximum height determined by the machine setting conditions cannot be obtained. Also, it is difficult to control the pile length to a desired length, and unevenness is likely to occur in the pile length.

[0007] An object of the present invention is to provide a pile fabric having different desired pile lengths of two or more steps uniformly throughout the target range of the fabric without being restricted by the manufacturing machine to be used and / or its setting conditions. [Means for Solving the Problems]

[0008] As a result of intensive studies to solve the above problems, the inventors of the present invention have reached the present invention. That is, the present invention includes the following preferred embodiments. [1] A pile fabric including a ground fabric portion and a pile portion composed of a plurality of cut pile yarns standing upright and constrained by the ground fabric portion, wherein the pile portion is composed of a plurality of two or more types of cut pile yarns having different pile lengths standing upright from the same root, which are derived from at least partially unravelled one covering yarn, and among the two or more types of cut pile yarns having different pile lengths, at least the cut pile yarn having the longest pile length is a false-twist yarn or a composite yarn including a false-twist yarn, and the ratio of the pile length of the longest cut pile yarn to the pile length of the shortest cut pile yarn among the two or more types of cut pile yarns standing upright from the same root is 1.10 to 1.90. [2] The pile fabric according to [1], wherein the breaking strength of all the cut pile yarns constituting the pile portion is 2 g / dtex or more. [3] The pile fabric according to [1] or [2], wherein all the cut pile yarns constituting the pile portion are false-twist yarns or composite yarns including false-twist yarns. [4] The ground fabric portion includes an unravelled covering yarn including a core yarn and one or more winding yarns wound around the core yarn, and two types of cut pile yarns having different pile lengths stand upright from the same root derived from one covering yarn in the pile portion. The pile fabric according to any one of [1] to [3]. [5] The unravelled covering yarn is a double covering yarn, and the two types of cut pile yarns constituting the pile portion are the outer winding yarn of the unravelled double covering yarn and the core yarn covered with the inner winding yarn. The pile fabric according to [4]. [6] Among the two types of cut piles standing upright from the same root, the cut pile yarn with a longer pile length is the outer winding yarn of the unravelled double covering yarn, and the cut pile yarn with a shorter pile length is the core yarn covered with the inner winding yarn of the unravelled double covering yarn. The pile fabric according to [4] or [5]. [7] The pile fabric according to any one of [1] to [3] above, comprising an unopened covering yarn including a core yarn and two or more winding yarns wound around the core yarn, and having three kinds of cut pile yarns with different pile lengths standing from the same root derived from one covering yarn in the raised hair portion. [8] The unopened covering yarn is a double covering yarn, and the three kinds of cut pile yarns constituting the raised hair portion are the outer winding yarn, the inner winding yarn, and the core yarn of the double covering yarn that has been opened, which is the pile fabric according to [7] above. [9] The pile fabric according to [8] above, wherein in the unopened double covering yarn, the inner winding yarn and the outer winding yarn are wound in opposite directions to each other.

[10] Among the three kinds of cut pile standing from the same root, the cut pile yarn with the longest pile length is the outer winding yarn of the opened double covering yarn, and the cut pile yarn with the shortest pile length is the core yarn of the opened double covering yarn, which is the pile fabric according to any one of [7] to [9] above.

[11] The pile fabric according to any one of [1] to

[10] above, which is a fabric for bedding, a wiping fabric, or a clothing fabric.

[12] A method for manufacturing the pile fabric according to any one of [1] to

[11] above, comprising: A step of preparing a covering yarn including a core yarn and one or more winding yarns wound around the core yarn; A step of implanting the covering yarn into a base fabric to produce a cut pile fabric including a raised hair portion composed of the covering yarn; and A step of opening the covering yarn constituting the raised hair portion of the cut pile fabric to produce a raised hair portion composed of two or more kinds of cut pile yarns with different pile lengths. including A method, wherein the winding yarn unwound in the step of unwinding the covering yarn is a false-twist yarn or a composite yarn including a false-twist yarn.

[13] The method according to

[12] above, wherein the covering yarn is a single covering yarn or a double covering yarn.

[14] The method according to

[12] , wherein the covering yarn is a double covering yarn, and in the step of unwinding the covering yarn, both the outer winding yarn and the inner winding yarn of the double covering yarn are unwound.

[15] The method according to

[12] , wherein the covering yarn is a double covering yarn, and in the step of unwinding the covering yarn, only the outer winding yarn of the double covering yarn is unwound.

[16] The method according to

[12] or

[14] , wherein the covering yarn is a double covering yarn, both the inner winding yarn and the outer winding yarn have torque, and each winding yarn is wound around the core yarn in a direction opposite to its own torque.

[17] The method according to

[15] , wherein the covering yarn is a double covering yarn, both the inner winding yarn and the outer winding yarn have torque, the inner winding yarn is wound around the core yarn in the same direction as its own torque, and the outer winding yarn is wound around the core yarn in a direction opposite to its own torque. [Effect of the Invention]

[0009] According to the present invention, it is possible to provide a pile fabric having different pile lengths of two or more stages uniformly over the entire target range of the fabric without being restricted by the manufacturing machine to be used and / or its setting conditions. [Brief Description of the Drawings]

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Embodiments for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present invention will be described in detail. Note that the scope of the present invention is not limited to the embodiments described here, and various modifications can be made without departing from the spirit of the present invention.

[0012] <Raised fabric> The raised fabric of the present invention includes a ground fabric part and a raised part composed of a plurality of cut pile yarns standing upright while being constrained by the ground fabric part. The raised part is composed of a plurality of two or more types of cut pile yarns having different raised lengths, which stand upright from the same root and are derived from at least partially loosened one covering yarn.

[0013] For example, the raised fabric 1 shown in FIG. 1 is composed of a raised portion 10 formed from cut pile yarns 11 with a long raised length and cut pile yarns 12 with a raised length shorter than that of the cut pile yarns 11, and a ground fabric portion 20 formed from weft yarns 21 and warp yarns 22. In the present disclosure, the ground fabric portion refers to a structure in which the basic components are assembled according to a certain rule so that the fabric or knitted fabric forms a planar body. For example, in the case of a fabric, it refers to a state in which the weft yarns and warp yarns are combined according to a certain rule. In the ground fabric portion 20, the covering yarn 13 is regularly constrained by the weft yarn 21 and the warp yarn 22. The cut pile yarns 11 and 12 constituting the raised portion 10 originate from a single covering yarn 13 and stand upright on the fabric surface through the ground fabric portion 20 from the same root 14.

[0014] Here, in the present disclosure, "standing upright" means a state in which the cut pile yarn penetrates through the ground fabric portion surrounded by the warp yarns and weft yarns and appears on the fabric surface. Also, "root" refers to the portion where the cut pile yarn penetrates through the ground fabric portion on the side where it stands upright. "Originating from a single covering yarn" means that when one end of the cut pile is pulled out from the ground fabric portion, the cut pile is derived from the same covering yarn. The "two or more types of cut pile yarns" mentioned here means that there are two or more cut pile yarns that are different in length (raised length). That is, due to the presence of the two or more types of cut pile in the raised portion of the present invention, there is a raised length difference of two or more levels.

[0015] FIG. 2 is a view of the raised fabric 1 shown in FIG. 1 as seen in the cross-sectional direction of the weft yarn 21. From the same root 14, two types of cut piles with different raised lengths derived from one covering yarn 13, namely, cut pile yarn 11 and cut pile yarn 12, penetrate the ground fabric part 20 and stand upright. The raised part 10 contains a plurality of roots 14, and a set of cut pile yarn 11 and cut pile yarn 12 stand upright from each of the plurality of roots 14. Two or more types of cut pile yarns with different raised lengths are obtained by unwinding the winding yarn of the covering yarn from which the cut pile yarn is derived. In the raised fabric of the present invention, usually, at one end or both ends of one covering yarn, there are 2 or more cut pile yarns with different lengths. A plurality of the covering yarns are constrained in the ground fabric part, and the raised part is constituted by a plurality of cut pile yarns derived from each covering yarn. In FIG. 2, the cut pile yarn 11 with a long raised length is derived from the winding yarn of the covering yarn 13, and the cut pile yarn 12 with a short raised length is derived from the core yarn of the covering yarn 13, and is obtained by unwinding the covering yarn 13 from the root 14 part.

[0016] In the raised fabric, each covering yarn is usually constrained at two or more positions in the ground fabric part, and when viewed in the weft cross-section, it can be constrained in a shape such as the letter U, V, or W of the alphabet. For example, in FIG. 2, it is constrained in a W shape. In any state of constraint, one covering yarn is unwound at both ends penetrating from the ground fabric part to form 2 or more cut pile yarns. Therefore, each covering yarn constrained in the ground fabric part usually has roots where cut pile yarns stand upright at both ends thereof. That is, each covering yarn constrained in the ground fabric part usually has two roots where cut pile yarns stand upright.

[0017] Conventionally, covering yarns have been used for various applications suitable based on the advantages of their structure in which the core yarn is covered with a sheath yarn. In the case of a pile fabric using a covering yarn, it has not been assumed to unwind and use the covering yarn (for example, the above Patent Documents 1 and 2). On the other hand, based on the relationship that the length of the winding yarn constituting the covering yarn is always longer than the length of the core yarn, the present invention provides a pile fabric with an unprecedented structure having a pile portion formed from cut pile derived from the unwound covering yarn. In such a pile fabric of the present invention, in the covering yarn used, by controlling the lengths of the core yarn and the winding yarn to a desired length in advance, without the need for a special machine and without changing the machine settings, a pile fabric having a plurality of different pile lengths can be efficiently produced. In particular, since it is possible to control the pile length of the cut pile yarn to a desired length by adjusting the length of the winding yarn, a pile length exceeding the height of the cut pile determined by the machine settings can be realized. Furthermore, since the pile length can be controlled by the length of the winding yarn, compared with the prior art, by setting the length of the knotting yarn (pile length) short when producing a cut pile fabric, while being advantageous in terms of work efficiency and cost, by unwinding the covering yarn, a pile fabric with a high pile height can be obtained more easily. Also, since the final pile length can be controlled at the stage of the covering yarn used in fabric production, compared with the method of creating a pile length difference by utilizing the shrinkage difference of fibers by heat treatment or solvent treatment after forming the fabric, a uniform pile length difference can be achieved more easily over the entire target range.

[0018] The number of cut pile yarns standing from a single root in the pile portion can be adjusted according to the number of winding yarns of the covering yarn used in the configuration of the pile portion and the number of these unwound. For example, in the double covering yarn 30 in which the inner winding yarn 32 and the outer winding yarn 33 are wound around the core yarn 31 as shown in FIG. 3, when the two winding yarns are unwound, as shown in FIG. 4, three cut pile yarns appear from the same root. If only the outer winding yarn is unwound in the double covering yarn, two cut pile yarns appear from the same root. Further, if a single covering yarn in which one winding yarn is wound around the core yarn is used, a pile fabric in which two yarns stand from the same root can be obtained.

[0019] The pile length of the cut pile yarns standing from a single root in the pile portion depends on the lengths of the core yarn and the winding yarns of the covering yarn used in the configuration of the pile portion. 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 as shown in FIG. 4. That is, for example, when the covering yarn is a single covering yarn, as shown in FIG. 5, a two-stage yarn length difference (the difference between the length of the core yarn and the length of the winding yarn) appears after the unwinding of the winding yarn. Similarly, for example, when the covering yarn is a double covering yarn and only the outer winding yarn is unwound, a two-stage yarn length difference (the difference between the length of the core yarn and the length of the outer winding yarn) appears after the unwinding of the outer winding yarn. Further, for example, when the covering yarn is a double covering yarn and all the winding yarns are unwound, as shown in FIG. 6, a three-stage 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. Due to the appearance of such a yarn length difference caused by the covering yarn used, in the pile fabric of the present invention, a pile length sufficiently longer than the height of the cut pile determined by the setting of the machine can be realized.

[0020] In the erected-pile fabric of the present invention, among two or more types of cut pile yarns erected from the same root, the ratio (longest cut pile yarn erected length / shortest cut pile yarn erected length) of the erected length of the longest cut pile yarn to the erected length of the shortest cut pile yarn is 1.10 to 1.90, preferably 1.20 to 1.80, more preferably 1.30 to 1.70, still more preferably 1.30 to 1.60, and particularly preferably 1.30 to 1.55. When the ratio of the erected lengths is at least the lower limit, a sufficient difference in the erected lengths of the cut pile yarns can be ensured in the erected portion. Further, when the ratio is at most the upper limit, a sufficient difference in the erected lengths can be ensured without causing pile collapse. There is also an advantage that the covering number in the covering yarn can be suppressed, leading to stable unwinding.

[0021] For example, when three types of cut pile yarns are erected from the same root, the ratio (second longest cut pile yarn erected length / shortest cut pile yarn erected length) of the erected length of the second longest cut pile yarn to the erected length of the shortest cut pile yarn can be appropriately determined according to the use of the erected-pile fabric and the like. In one embodiment of the present invention, for example, it is preferably in the range of preferably 1.05 to 1.80, more preferably 1.10 to 1.70, still more preferably 1.10 to 1.60, and particularly preferably 1.10 to 1.50.

[0022] The ratio of the pile lengths is calculated as the ratio of the pile length of the longest cut pile yarn to the pile length of the shortest cut pile yarn among two or more types of cut pile yarns standing upright from the same root. In the present invention, the pile length of the cut pile yarn refers to the length from the surface of the ground fabric on the side where the cut pile yarn stands upright to the tip of the cut pile yarn. In the present invention, for example, as shown in FIG. 7, the pile length of the cut pile yarn can be measured by cutting out 20 cm along the warp so as to generally include three rows of the pile yarns of the ground fabric as seen from the back surface of the pile fabric, and measuring the lengths of the long and short cut pile yarns included in this range using, for example, a ruler or a measuring tape. At this time, in order not to overly stretch the cut pile yarn, for example, as shown in FIG. 8, the ruler is pressed against the cut pile yarns in a state where the rows of the cut pile yarns are laid down horizontally for measurement. In the measurement shown in FIG. 8, using a ruler with a minimum scale of 1.0 mm, the length from the root part to the tip part of each cut pile yarn is visually read to 1 / 10 of the scale. The scale of the ruler used for measurement may be appropriately selected according to the length of the cut pile yarn to be measured. For the lengths of the measured cut pile yarns, the ratio of the pile lengths is calculated for each set of cut pile yarns standing upright from the same root, and the ratio of the pile lengths in the present invention can be obtained as the average value of the ratios of all the sets included in the range to be measured. Specifically, it can be measured according to the method described in the examples described later.

[0023] In the raised fabric of the present invention, in which the difference in the length of the raised cut pile yarns is expressed by the unwinding of the covering yarn, since the difference in the length of the raised cut pile yarns can be controlled by the design of the covering yarn, the variation in the difference in the length of the raised cut pile yarns between each root (hereinafter, also simply referred to as "variation in the difference in the length of the raised cut pile yarns") can be reduced. Therefore, in the raised fabric of the present invention, as compared with the method of obtaining the difference in the length of the raised cut pile yarns by utilizing the difference in the shrinkage of the fibers by heat treatment or solvent treatment after forming the fabric, it is possible to more easily achieve a uniform difference in the length of the raised cut pile yarns over the entire target range. In the raised fabric of the present invention, it is preferable that the cut pile yarns having a uniform difference in the length of the raised cut pile yarns, both long and short, are erected from substantially all the roots where the cut pile yarns are erected. When there is almost no variation or the variation is small in the difference in the length of the raised cut pile yarns, a raised fabric excellent in texture, appearance, etc. is obtained. The variation in the difference in the length of the raised cut pile yarns can be evaluated, for example, using the coefficient of variation of the ratio of the length of the longest cut pile yarn to the length of the shortest cut pile yarn among two or more types of cut pile yarns erected from the same root as an index. The smaller the coefficient of variation, the more uniform the difference in the length of the raised cut pile yarns becomes.

[0024] The coefficient of variation can be calculated, for example, as follows. Cut out an arbitrary measurement range from the raised fabric, and measure the length of each cut pile yarn included in the range in the same manner as the measurement of the ratio of the length of the longest cut pile yarn to the length of the shortest cut pile yarn at the same root described above. Calculate the ratio of the length of the raised cut pile yarns for each set of cut pile yarns erected from the same root, and obtain it based on the average value and the standard deviation of the entire measurement range. Specifically, it can be measured according to the method described in the examples described later.

[0025] In the raised fabric of the present invention, among two or more types of cut pile yarns having different raised lengths, at least the cut pile yarn having the longest raised length is a false-twist yarn or a composite yarn containing a false-twist yarn (hereinafter, also referred to as "false-twist yarn-containing composite yarn"), or is composed of these, and preferably, substantially all of the cut pile yarns constituting the raised portion are false-twist yarns or false-twist yarn-containing composite yarns, or are composed of these. In the present disclosure, the false-twist yarn means a false-twist yarn commonly used in the art, that is, a processed yarn manufactured by the false-twist method. In the present disclosure, the false-twist yarn-containing composite yarn means a yarn in which the 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. In the present invention, the false-twist yarn or false-twist yarn-containing composite yarn constituting the cut pile yarn of the raised portion preferably has bulkiness (that is, is not non-bulky) from the viewpoints of the volume of the cut pile yarn constituting the raised portion and the unwindability from the covering yarn during the production of the raised fabric. In the present disclosure, the "bulky" false-twist yarn or false-twist yarn-containing composite yarn means, for example, those having a crimp elongation rate of 10% or more. In one embodiment of the present invention, the false-twist yarn or false-twist yarn-containing composite yarn preferably has a crimp elongation rate of 12% or more, more preferably 15% or more, and still more preferably 20% or more. The upper limit value of the crimp elongation rate of the cut pile yarn is not particularly limited, but is usually 60% or less, preferably 40% or less, from the viewpoints of handleability and workability. The crimp elongation rate 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 false-twist conditions of the yarn. The crimp elongation rate can be measured, for example, by the same method as the method for measuring the crimp elongation rate of the covering yarn in the examples described below. The crimp elongation rate of the cut pile yarn in the present invention may be measured in the cut pile yarn constituting the raised fabric or may be measured as the crimp elongation rate in the covering yarn that is the constituent material of the raised fabric. Hereinafter, when there is substantially no change in the physical properties of the covering yarn that is the constituent material of the raised fabric, the physical properties thereof can be regarded as the physical properties of the cut pile yarn of the raised fabric.

[0026] Depending on the setting of the false twist number in the false twisting method, there are false twisted yarns without torque or with low torque, or false twisted yarns with high torque. Further, non-torque false twisted yarns that substantially have no torque are produced by simultaneously winding two false twisted yarns with opposite twisting directions in the twisting-thermosetting process, or by fixing the torque originally possessed by the false twisted yarn by dyeing the false twisted yarn. As described above, the pile fabric of the present invention is composed of a plurality of cut pile yarns derived from the unwound covering yarn. By selecting the torque and the winding direction of the winding yarn constituting this covering yarn, the unwinding property of the covering yarn can be controlled, and a pile fabric having pile portions in various modes as described later can be obtained. In one embodiment of the present invention, it is preferable that the cut pile yarn (false twisted yarn or false twisted yarn-containing composite yarn) having the longest pile length, which is derived from the outermost winding yarn of the covering yarn, has torque. Even in the case of a false twisted yarn that has been dyed and has become non-torque, by applying after-twisting to this and selecting the after-twisting direction and the winding direction in the covering yarn, the unwinding property of the covering yarn can be controlled in the same manner as in the case of using a false twisted yarn having torque. Therefore, when using a dyed false twisted yarn, it is preferable to use an after-twisted false twisted yarn. The after-twisting can be performed by a conventionally known method.

[0027] In the pile fabric of the present invention, among two or more types of cut pile yarns having different pile lengths, the cut pile yarns other than the cut pile yarn having the longest pile length may be, for example, spun yarns, false twisted yarns, or false twisted yarn-containing composite yarns. From the viewpoints of the standing property of the cut pile yarn and the volume of the pile portion, it is preferable that substantially all of the cut pile yarns constituting the pile portion are false twisted yarns or false twisted yarn-containing composite yarns, or are composed including these. In this case, the crimp elongation rate and the presence or absence of torque of the false twisted yarn or the false twisted yarn-containing composite yarn are not particularly limited, but the same mode as the embodiment in the outer winding yarn described above can be applied.

[0028] In the raised fabric of the present invention, it is preferable that the breaking strength of all cut pile yarns constituting the raised portion is 2 g / dtex or more. When the breaking strength of the cut pile yarn is 2 cN / dtex or more, it is possible to suppress a part of the fibers constituting the cut pile yarn from falling off during the unwinding of the covering yarn and / or during the fibrillation of the cut pile yarn. Thereby, a raised fabric excellent in texture and appearance can be obtained. From the viewpoint of suppressing the fiber shedding, the breaking strength of the cut pile 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 cut pile yarn is not particularly limited, but is usually 7.0 cN / dtex or less. The breaking strength of the cut pile yarn can be measured according to JIS L 1013:2021. Further, the breaking strength of the cut pile yarn usually does not significantly decrease from the breaking strengths of the core yarn and the wrapping yarn of the covering yarn used. Therefore, for example, by using a covering yarn composed of a core yarn and a wrapping yarn having a breaking strength higher than 2 cN / dtex as a material, the breaking strength of the cut pile yarn in the raised fabric can usually be made 2 cN / dtex or more. In the present disclosure, unwinding the wrapping yarn of the covering yarn from the core yarn (generally, an operation acting on the fiber bundle) is referred to as unwinding. Regardless of whether the cut pile yarn is derived from the covering yarn, for example, in the finishing process of the raised fabric, etc., in order to give texture and volume, the fibers of the cut pile yarn are opened by a card cloth or the like (also called hair splitting, generally an operation of separating the constituent fibers into single yarns), which is referred to as fibrillation. Therefore, depending on the processing method, unwinding and fibrillation may be performed simultaneously.

[0029] The polymers constituting the cut pile yarns that make up the raised hair portion can be appropriately determined according to the use of the raised fabric, etc. Examples of the polymers 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 (for example, isophthalic acid and / or 5-sodium sulfoisophthalic acid); polymers kneaded with a functional agent (for example, deodorant and / or flame retardant); 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. Each cut pile yarn may be composed of one type of polymer or two or more types of polymers, and may be, for example, a core-sheath type, a split 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.

[0030] The cross-sectional shape of the cut pile yarns that make up the raised hair portion is not particularly limited, and may be, for example, a round cross-section, flat, multi-filament shape, or a mixed cross-section of irregular shapes.

[0031] The single-filament fineness of the cut pile yarns that make up the raised hair portion can be appropriately determined according to the use of the raised fabric, the grade of the product group, etc. The single-filament fineness of the cut pile yarns may be, for example, 0.05 to 60 dtex, preferably 0.1 to 12 dtex.

[0032] The pile lengths of the cut pile yarns that make up the raised hair portion can be appropriately determined according to the use of the raised hair fabric, the grade of the product group, etc. The pile lengths of the respective cut pile yarns are determined such that the ratio of the longest pile length to the shortest pile length among the cut piles standing from the same root falls within the range described above. For example, among the plurality of types of cut pile yarns that make up the raised hair portion, the pile length of the longest cut pile may be, for example, 10 to 30 mm, preferably 12 to 20 mm. Also, among the plurality of types of cut pile yarns that make up the raised hair portion, the pile length of the shortest cut pile may be, for example, 7 to 15 mm, preferably 8 to 12 mm. The pile lengths of the respective cut pile yarns can be measured according to the method described above in the method for measuring the pile length ratio of the cut pile yarns.

[0033] In one embodiment of the present invention (hereinafter, also referred to as the "first embodiment"), the ground fabric portion includes an unopened covering yarn including a core yarn and one or more winding yarns wound around the core yarn, and two types of cut pile yarns having different pile lengths stand from the same root derived from one covering yarn in the raised hair portion. FIG. 5 is a schematic view of a yarn having a set of cut pile yarns with different pile lengths at both ends, which constitutes the raised hair fabric of the present invention in the first embodiment, as viewed in the cross-sectional direction of the weft. In FIG. 5, the yarn 15 is constrained by the weft 21 to form the ground fabric portion 20, and at both ends of the yarn 15, a set of cut pile yarns 11 and 12 having different pile lengths stand through the ground fabric portion 20 from the same root. In the first embodiment, the portion of the yarn 15 constrained by the ground fabric portion 20 exists as a covering yarn 13 in a state where one or more winding yarns are wound around the core yarn (that is, an unopened state). On the other hand, in the raised hair portion 10, the covering yarn is opened and exists as cut pile yarns 11 and 12.

[0034] In the first aspect, the unwound covering yarn 13 may be, for example, a double covering yarn. In this case, the unwound covering yarn 13 is composed of a core yarn and two winding yarns wound around the core yarn. The two types of cut pile yarns 11 and 12 that constitute the raised hair portion 10 in FIG. 5 are respectively derived from the outer winding yarn of the unwound double covering yarn and the core yarn covered with the inner winding yarn. This aspect (hereinafter also referred to as "Embodiment 1-1") can be achieved by unwinding only the outer winding yarn of the double covering yarn. Among the two types of cut piles 11 and 12 standing from the same root 14 in the raised hair fabric of this aspect, the cut pile yarn 11 with a longer raised hair length is derived from the outer winding yarn of the unwound double covering yarn, and the cut pile yarn 12 with a shorter raised hair length is derived from the core yarn covered with the inner winding yarn.

[0035] In the first aspect, the unwound covering yarn 13 may be, for example, a single covering yarn. In this case, the unwound covering yarn 13 is composed of a core yarn and one winding yarn wound around the core yarn. The two types of cut pile yarns 11 and 12 that constitute the raised hair portion 10 in FIG. 5 are respectively derived from the winding yarn of the unwound single covering yarn and the core yarn of the single covering yarn. This aspect (hereinafter also referred to as "Embodiment 1-2") can be achieved by unwinding the single covering yarn. Among the two types of cut piles 11 and 12 standing from the same root 14 in the raised hair fabric of this aspect, the cut pile yarn 11 with a longer raised hair length is derived from the winding yarn of the unwound single covering yarn, and the cut pile yarn 12 with a shorter raised hair length is derived from the core yarn.

[0036] In another embodiment of the present invention (hereinafter also referred to as the "second embodiment"), the ground tissue part includes an unwound covering yarn including a core yarn and two or more winding yarns wound around the core yarn, and at the erected hair part, three types of cut pile yarns having different erected hair lengths from the same root derived from one covering yarn are erected. FIG. 6 is a schematic view of a yarn strip having a set of cut pile yarns with different erected hair lengths at both ends, which constitutes the erected hair fabric of the present invention in the second embodiment, as viewed from the cross-sectional direction of the weft yarn. In FIG. 6, the yarn strip 15 is constrained by the weft yarn 21 to form the ground tissue part 20, and at both ends of the yarn strip 15, the ground tissue part 20 is penetrated respectively, and a set of cut pile yarns 11-1, 11-2 and 12 with different erected hair lengths from the same root are erected. In the second embodiment, the portion of the yarn strip 15 constrained by the ground tissue part 20 exists as a covering yarn 13 in a state where two or more winding yarns are wound around the core yarn (that is, an unwound state). On the other hand, in the erected hair part 10, the covering yarn is unwound and exists as cut pile yarns 11-1, 11-2 and 12.

[0037] In the second embodiment, the unwound covering yarn 13 is preferably a double covering yarn. In this case, the unwound covering yarn 13 is composed of a core yarn and two winding yarns wound around the core yarn, and the three types of cut pile yarns 11-1, 11-2 and 12 constituting the erected hair part 10 are derived from the outer winding yarn, the inner winding yarn, and the core yarn of the unwound double covering yarn respectively. This embodiment (hereinafter also referred to as "Embodiment 2") can be achieved by unwinding the double covering yarn. Among the three types of cut pile 11-1, 11-2 and 12 erected from the same root 14 in the erected hair fabric of this embodiment, the cut pile yarn 11-1 with the longest erected hair length is the outer winding yarn of the unwound double covering yarn, the cut pile yarn 11-2 with the second longest erected hair length is the inner winding yarn, and the cut pile yarn 12 with the shortest erected hair length is derived from the core yarn. Further, in the unwound covering yarn 13, it is preferable that the inner winding yarn and the outer winding yarn are wound in opposite directions to each other.

[0038] <Method for manufacturing erected hair fabric> The erected hair fabric of the present invention is, for example, A step of preparing a covering yarn including a core yarn and one or more winding yarns wound around the periphery thereof (hereinafter, also referred to as "covering yarn preparation step"), A step of implanting the covering yarn into a base fabric to produce a cut pile fabric including a raised portion composed of the covering yarn (hereinafter, also referred to as "cut pile fabric production step"), and A step of unraveling the covering yarn constituting the raised portion of the cut pile fabric to produce a raised portion composed of two or more types of cut pile yarns having different raised lengths (hereinafter, also referred to as "raised portion production step") can be produced by a method including the above steps.

[0039] (Covering Yarn Preparation Step) In the production of the raised fabric of the present invention, a covering yarn including a core yarn and one or more winding yarns wound around the periphery thereof and capable of unraveling at least the outermost winding yarn can be used. By unraveling the winding yarn of the covering yarn, a raised fabric of the present invention in which two or more types of cut pile yarns standing from the same root can be formed. The covering yarn used in the present invention can be produced from conventionally known materials by conventionally known methods as long as two or more types of cut pile yarns standing from the same root have the above-mentioned raised length ratio after unraveling after forming the fabric. For example, by appropriately selecting the configuration of the covering yarn such as the fineness of the constituent fibers, the covering number, and the winding direction of the winding yarn, the unravelability of the covering yarn can be controlled to obtain a raised fabric including a raised portion in a desired form. In the covering yarn that can be used for producing the raised fabric of the present invention, the core yarn does not necessarily have to be completely covered with the winding yarn. This is because, in the present invention, there is no purpose in the conventional covering yarn such as protecting the core yarn.

[0040] In the covering yarn used for manufacturing the pile fabric of the present invention, the ratio of the length of the outermost winding yarn to the length of the core yarn is preferably 1.10 to 1.90. When the ratio of the length of the core yarn to the length of the outer winding yarn in the covering yarn is within the above range, the ratio of the pile length of the longest cut pile yarn to the pile length of the shortest cut pile yarn, which stand upright from the same root after unwinding the winding yarn, can be controlled within the predetermined range. Also, it is advantageous in terms of ease of unwinding the covering yarn. The above ratio can be appropriately determined according to the pile length of the cut pile yarn in the finally desired pile fabric. However, from the viewpoints of unwindability of the winding yarn and easier obtaining of a pile fabric having a sufficient pile length difference, it is more preferably 1.20 to 1.80, still more preferably 1.30 to 1.70, particularly preferably 1.30 to 1.60, and especially preferably 1.30 to 1.55.

[0041] For example, when there are multiple winding yarns such as in the case of a double covering yarn, the ratio of the length of the inner winding yarn to the length of the core yarn is preferably 1.05 to 1.80, more preferably 1.07 to 1.70, still more preferably 1.08 to 1.60, and particularly preferably 1.10 to 1.50. When the ratio of the length of the inner winding yarn to the length of the core yarn is within the above range, the covering yarn has excellent unwindability, and a pile fabric having a sufficient pile length difference can be obtained. Generally, the larger the ratio of the inner winding yarn to the core yarn, the smaller the fineness and the tighter the winding around the core yarn.

[0042] The ratio of the lengths of the core yarn and the winding yarn constituting the covering yarn is calculated as the ratio by measuring the lengths of the core yarn and the winding yarn of one covering yarn respectively. The lengths of the core yarn and the winding yarn in the covering yarn can be measured, for example, after cutting the covering yarn to be measured into a predetermined length, unwinding the covering yarn so that no excessive tension is applied, and applying a constant tension (for example, a tensile tension of 2 cN or less) to the yarn to be measured. Specifically, it can be measured according to the method described in the examples below.

[0043] The ratio of the length of the winding yarn to the length of the core yarn can be adjusted by appropriately selecting, for example, the fineness of the core yarn, the fineness of the winding yarn, and the covering number of the winding yarn (the number of rotations of the winding yarn per 1 meter of the covering yarn). An example of the method for adjusting the above ratio will be described by taking the case of manufacturing a single covering yarn as an example. Fig. 9 shows a schematic diagram showing the arrangement of the core yarn 42 and the winding yarn 43. The left diagram in Fig. 9 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 41. The central diagram in Fig. 9 is a schematic diagram when the winding yarn 43 (ends are A and B) is wound around the core yarn 42 in one turn at the helix angle θ1 (radian) of the winding yarn, and the right diagram in Fig. 9 is a schematic diagram of the winding yarn before the winding yarn 43 (ends are A' and B') is wound around the core yarn 42 at the helix angle θ1 of the winding yarn. In addition, in Fig. 9 and Figs. 11 and 12 described later, for the sake of easy viewing of the drawings, the dimensions, ratios, etc. of each component are appropriately made different. Since the line segment A'C corresponds to (the diameter of the winding yarn 43 + the diameter of the core yarn 42 + the diameter of the winding yarn 43) × π and the line segment B'C corresponds to 1 / T (T [t / m] is the covering number of the winding yarn 43), tanθ1 is represented by the following formula. tanθ1=(1 / T) / {(the diameter of the winding yarn 43 + the diameter of the core yarn 42 + the diameter of the winding yarn 43) × 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 represented 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 represented 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 nylon (specific gravity: 1.14) or olefin (specific gravity: 0.91 - 0.98), the relationship between the fineness and the diameter d is generally expressed by the following formula: d [μm] = 11 × (fineness) 1 / 2 or d [μm] = 12 × (fineness) 1 / 2 Since it is expressed in this way, when the core yarn or the winding yarn is nylon or olefin, these formulas can be applied to the above formula by replacing d [μm] = 10 × (fineness). 1 / 2 Even when the core yarn or the winding yarn is other than polyester, nylon, and olefin, since the relational expression between the fineness 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 right figure in Fig. 9, the ratio of the length of the winding yarn 43 to the length of the core yarn 42 is expressed 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 fineness of the core yarn, the fineness of the winding yarn, and / or the covering number of the winding yarn.

[0044] In the left figure of Fig. 9, it is assumed that the core yarn 42 and the winding yarn 43 are in a non - deformed cylindrical shape, but in reality, usually, the core yarn 42 and the winding yarn 43 are deformed to some extent from the cylindrical shape. Also, in the central and right figures of Fig. 9, the diameter of the winding yarn 43 is not considered. However, it has been confirmed that the tanθ or the yarn length ratio calculated using Formulas (1) and (2) agrees well with the tanθ or the yarn length ratio actually measured from the manufactured covering yarn. Therefore, Formulas (1) and (2) can be used to obtain the desired yarn length ratio or to determine the covering number or the helix angle of the winding yarn.

[0045] 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 about 100 to 180 °C, for example, about 150 °C). When weaving or knitting the pile fabric of the present invention, it is also preferable to perform heat treatment after weaving or knitting. Therefore, by obtaining the ratio of the length of the wrapping yarn to the length of the core yarn of such a covering yarn after such heat treatment, it may be possible to evaluate the ratio of the length of the wrapping yarn to the length of the core yarn that is closer to the ratio of the yarn lengths when actually manufacturing the pile fabric. The ratio of the length of the wrapping yarn to the length of the core yarn of the covering yarn after heat treatment tends to be smaller compared to the same ratio in the covering yarn before heat treatment. Therefore, in one embodiment of the present invention, for example, using a covering yarn in which the ratio of the length of at least the outermost wrapping yarn to the length of the core yarn after heat treatment at 150 °C for 3 minutes is, for example, 1.10 to 1.80 or 1.15 to 1.70, may be advantageous from the viewpoints of ensuring a desired pile length difference and spinnability. Similarly, it may be advantageous to use a covering yarn in which the ratio of the length of the inner wrapping yarn to the length of the core yarn after heat treatment at 150 °C for 3 minutes is, for example, 1.02 to 1.80 or 1.05 to 1.70. 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 wrapping yarn to the length of the core yarn of the above-mentioned covering yarn, except that the measurement object is changed from the covering yarn to the covering yarn after heat treatment.

[0046] The ratio of the length of the wrapping yarn to the length of the core yarn of the covering yarn after heat treatment at 150 °C for 3 minutes can be controlled, for example, by adjusting the structure of the covering yarn (for example, the covering number, the helix angle of the wrapping yarn) according to the types, fineness, heat shrinkage rate, etc. of the core yarn and the wrapping yarn used for the covering yarn. By measuring in advance the heat shrinkage rates of the core yarn and the wrapping yarn before and after heat treatment under the heat treatment conditions when manufacturing the pile fabric, it is possible to more accurately determine the setting value (covering number of the wrapping yarn) of the covering yarn manufacturing apparatus for obtaining the desired yarn length ratio after heat treatment under the predetermined conditions.

[0047] 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 perspective 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 perspective of knitting and weaving properties, 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, for example, based on an image of the covering yarn magnified and photographed by a digital microscope.

[0048] [Winding yarn] For all the winding yarns, the breaking strength of each winding yarn is, for example, 2 cN / dtex or more, preferably more than 2 cN / dtex, more preferably 2.1 cN / dtex or more, still more preferably 2.5 cN / dtex or more, particularly preferably 3.0 cN / dtex or more, and most preferably 3.3 cN / dtex or more. When the breaking strength of the winding yarn is above the above lower limit, it is possible to suppress a part of the fibers constituting the cut pile yarn from falling off during the unwinding of the covering yarn and / or during the fibrillation of the cut pile yarn. Thereby, a pile fabric excellent in texture and appearance can be obtained. The upper limit of the breaking strength of the winding yarn is not particularly limited, but it is usually 7.0 cN / dtex or less. The breaking strength of the winding yarn can be measured according to JIS L 1013:2021.

[0049] For all the winding yarns, the fineness of each winding yarn is preferably 165 - 1000 dtex, more preferably 200 - 900 dtex, still more preferably 250 - 600 dtex, and particularly preferably 300 - 500 dtex. When the fineness of the winding yarn is within the above range, the standing property of each cut pile yarn obtained after unwinding is excellent, and a pile part having a sufficient pile length difference can be formed. The fineness of the winding yarn can be measured according to JIS L 1013:2021.

[0050] The outermost winding yarn of the covering yarn is a false-twist yarn or a composite yarn containing a false-twist yarn. As the false-twist yarn or the composite yarn containing a false-twist yarn, those satisfying the physical properties and characteristics such as the breaking strength, the crimp elongation rate, and the torque that the at least cut pile yarn having the longest pile length, which is described above as constituting the raised fabric of the present invention, has are preferable.

[0051] In the production of the raised fabric of the present invention, it is preferable to use a covering yarn in which the outermost winding yarn (false-twist yarn or composite yarn containing a false-twist yarn) has torque and the winding yarn is wound around the core yarn in the direction opposite to the 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, when the winding yarn is wound in the same direction as its torque, generally, the unwinding of the winding yarn tends to be difficult.

[0052] Further, the inventors have found that the larger the torque of the winding yarn wound in the direction opposite to its own torque, the more the unwindability of the winding yarn can be ensured even when the covering number of the winding yarn is set high. Since an increase in the covering number brings about an increase in the ratio of the length of the winding yarn to the length of the core yarn, the larger the torque of the winding yarn wound in the direction opposite to its own torque, the larger the ratio of the length of the winding yarn to the length of the core yarn can be made while ensuring the unwindability of the winding yarn. From this viewpoint, the false-twist yarn or the composite yarn containing a false-twist 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 burrs (snarls) and handleability. The torque in the present invention can be measured by the method described in the examples below.

[0053] When there are a plurality of wound yarns, examples of the types of yarns constituting the inner wound yarns include spun yarns, false-twisted yarns, and composite yarns containing false-twisted yarns. Among these, from the viewpoint of the standing property of cut pile yarns, false-twisted yarns or composite yarns containing false-twisted yarns are preferred. 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-twisted yarn or composite yarn containing false-twisted yarn as the inner wound yarn are not particularly limited. From the viewpoint of the unwinding property of the inner wound yarn or from the viewpoint of a larger yarn length difference between the core yarn and the inner and outer wound 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-twisted yarn or composite yarn containing false-twisted yarn as the inner wound yarn can be in the same form as those of the false-twisted yarn or composite yarn containing false-twisted yarn as at least the outermost wound yarn described above.

[0054] In one embodiment of the present invention, the wound yarns intended to be unwound in the manufacturing process of the pile fabric, preferably all the wound yarns of the covering yarn forming the pile fabric, are false-twisted yarns or composite yarns containing false-twisted yarns. In this one embodiment, the types and physical properties of each wound yarn may be the same or different. As the embodiment of at least the outermost wound yarn in this embodiment, the above-described embodiment of the outermost wound yarn, particularly the preferred embodiment, can be adapted. As the embodiment of the inner wound yarn when there are a plurality of wound yarns in this embodiment, the above-described embodiment of the inner wound yarn, particularly the preferred embodiment, can be adapted.

[0055] For winding yarns other than the outermost winding yarn, when the false-twist yarn or the composite yarn containing false-twist yarn that constitutes 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. This is presumably due to the fact that it is difficult to form a space at the interface between the winding yarn and the yarn to be wound by winding in the same direction as the torque of the yarn. 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. For example, the above-described Embodiment 1-1 can be obtained by using a double covering yarn in which the inner winding yarn is wound around the core yarn in the same direction as its own torque.

[0056] For winding yarns other than the outermost winding yarn, when the false-twist yarn or the composite yarn containing false-twist yarn that constitutes 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. This is presumably due to the fact that it physically acts to form a space at the interface between the winding yarn and the yarn to be wound by winding in the opposite direction to the torque of the yarn. Also, the greater the torque of the winding yarn wound in the opposite direction to its own torque, the more 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 greater 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. For example, the above-described Embodiment 1-2 can be obtained by using a single covering yarn in which the winding yarn is wound around the core yarn in the opposite direction to its own torque. Also, the above-described Embodiment 2 can be obtained by using a double covering yarn in which the inner winding yarn and the outer winding yarn are each wound in the opposite direction to their own torques.

[0057] In one embodiment of the present invention, the pile fabric is formed using a single covering yarn.

[0058] In another embodiment of the present invention, the pile fabric is formed using double covering yarns. Furthermore, by changing the configuration of the double covering yarns as follows, pile fabrics of various embodiments can be obtained. For example, by using a double covering yarn in which the inner winding yarn is wound in the opposite direction to its own torque, in addition to the outer winding yarn, the inner winding yarn can also be unwound as desired. Thereby, a pile fabric can be obtained in which three types of cut pile yarns having different pile lengths from the same root are erected.

[0059] Also, by using a double covering yarn in which the inner winding yarn is wound in the same direction as its own torque, the outer winding yarn can be unwound as desired, and the inner winding yarn can be designed to be difficult to unwind as desired. Thereby, a pile fabric can be obtained in which two types of cut pile yarns having different pile lengths from the same root are erected.

[0060] A double covering yarn in which the inner winding yarn and the outer winding yarn are wound in opposite directions to each other can be handled without fluffing. Such an embodiment is particularly preferable in the case of a design intended to unwind both the outer winding yarn and the inner winding yarn, but can also be applied to the case of a design intended to unwind only the outer winding yarn and not the inner winding yarn.

[0061] Also, a double covering yarn in which the inner winding yarn and the outer winding yarn are wound in the same direction can be used. Such an 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 can also be applied to the case of a design intended to unwind both the outer winding yarn and the inner winding yarn.

[0062] The descriptions of the torque and winding direction of the winding yarn up to this point are, in principle, suitable relationships when heating is not performed on the false-twisted yarn or the false-twisted yarn-containing composite yarn (abbreviated as false-twisted yarn etc.) before dyeing or producing the 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 substantially become a non-torque false-twisted yarn etc. When using such a false-twisted yarn etc. for the covering yarn, it is preferable to twist (super-twist) the false-twisted yarn etc. alone to generate torque again. In this case, the direction in which the torque is generated is the opposite direction to the twisting direction. That is, when twisted in the Z direction, an 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-twisting 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-twisting direction of the false-twisted yarn etc. Such a relationship is not limited to the case of a 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 above can be obtained by twisting this alone and winding it in the twisting direction.

[0063] In one embodiment of the present invention, regarding the winding yarn when using a single covering yarn in the production of a pile fabric, or the inner winding yarn when using 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, where 165 dtex ≤ D1 ≤ 1100 dtex and 165 dtex ≤ D2 ≤ 660 dtex.] It can be represented by any of the following. 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 direction opposite 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.

[0064] 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 more favorably unwound.

[0065] Conversely, when using a double covering yarn and intending that the inner winding yarn is not unwound, if T1 × (total fineness) in formulas (I) to (III) 1 / 2 is less than the lower limit value or exceeds the upper limit value, the inner winding yarn can be designed not to be unwound.

[0066] In one embodiment of the present invention, regarding the outer winding yarn when using double covering yarn in the production of a pile fabric, 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 can be represented by any of them.

[0067] 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 value in the above formula (VII) is preferably 8500 or more (for example, 8600 or more or 8700 or more), and the upper limit value 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 value and not more than the upper limit value, the outer winding yarn in the case of the double covering yarn can be more favorably unwound.

[0068] 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.

[0069] 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. 10 and 11. FIG. 10 shows a covering yarn that can be used in the present invention. After winding the covering yarns on cardboard little by little so that they do not overlap and applying a tensile tension of 2 cN or more, 11 arbitrarily selected adjacent covering yarns are photographed at a magnification of 100 times with a magnifying glass (model number VHX-5000) manufactured by Keyence Corporation. First, in the image of each covering yarn, a representative zigzag line 44 is drawn, and the distance d1 is measured at 5 locations (only 1 location is shown in FIG. 10 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 45 (broken lines) are drawn along the winding yarn, and the distance 46 (corresponding to the distance of the winding yarn) (μm) between adjacent straight lines 45 is measured (only 1 location is shown in FIG. 10 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. 10, for easy viewing, auxiliary lines (such as straight lines 44 to 46) 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.

[0070] 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 helical angle θ3 (radian) (see FIG. 9). In FIG. 11, 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. 11, since θ3' corresponds to the helical angle θ3, sinθ3 is expressed by the following formula. sinθ3 = (length of line segment EF) / (length of line segment EG) Here, since the length of the line segment EG is equal to π × (the diameter d2 of the covering yarn), sinθ3 = (the length of the line segment EF) / (πd2) By substituting the distance between adjacent winding yarns obtained from FIG. 10 as the length of the line segment EF and substituting the diameter of the covering yarn obtained from FIG. 10 as d2, the helical angle θ3 can be obtained.

[0071] The polymer constituting the winding yarn is not particularly limited. The type of the polymer constituting the winding yarn, as well as the constitution, cross-sectional shape, and single-filament fineness of the winding yarn, etc. may be the same as those of the cut pile yarn constituting the raised fabric.

[0072] [Core yarn] The breaking strength of the core yarn is, for example, 2 cN / dtex or more, preferably more than 2 cN / dtex, more preferably 2.1 cN / dtex or more, still more preferably 2.5 cN / dtex or more, and particularly preferably 2.7 cN / dtex or more. When the breaking strength of the core yarn is at the above lower limit or more, it is possible to suppress a part of the fibers constituting the cut pile yarn from falling off during the unwinding of the covering yarn and / or during the fibrillation of the cut pile yarn, etc. Thereby, a raised fabric excellent in texture and appearance can be obtained. The upper limit 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 in accordance with JIS L 1013:2021, similar to the breaking strength of the winding yarn.

[0073] The fineness of the core yarn is preferably 165 to 1500 dtex, more preferably 200 to 1200 dtex, still more preferably 300 to 800 dtex, and particularly preferably 400 to 600 dtex. When the fineness of the core yarn is in the above range, the cut pile yarn obtained after unwinding has excellent standing properties, and a raised portion having a sufficient raised hair length difference can be formed. The fineness of the core yarn can be measured in accordance with JIS L 1013:2021, similar to the fineness of the winding yarn.

[0074] It has been found that the unwindability of the wrapped yarn can be ensured even when the covering number of the wrapped yarn is set high as long as the fineness of the core yarn is large when the fineness of the wrapped yarn is constant. That is, the difference between the length of the core yarn and the length of the wrapped yarn can be increased. On the other hand, it has been found that the unwindability of the wrapped yarn can be ensured even when the covering number is set high as long as the fineness of the wrapped yarn is large when the fineness of the core yarn is constant.

[0075] The type of yarn constituting the core yarn is not particularly limited, and examples thereof include spun yarns, false-twisted yarns, and composite yarns containing false-twisted yarns. Among these, from the viewpoint of the standing property of the obtained cut pile yarn, false-twisted yarns or composite yarns containing false-twisted yarns are preferred.

[0076] The crimp elongation rate of the false-twisted yarn or the composite yarn containing a false-twisted yarn as the core yarn is not particularly limited, but from the viewpoints of ensuring a sufficient difference in the length of the raised hair in the raised fabric and the volume of the raised part, etc., those that satisfy the physical properties and characteristics such as the crimp elongation rate and torque of the cut pile yarn described above that constitutes the raised fabric of the present invention are preferred.

[0077] In addition, the presence or absence of torque and the magnitude of torque of the false-twisted yarn or the composite yarn containing a false-twisted yarn as the core yarn are not particularly limited, but from the viewpoint of suppressing the occurrence of pills, it preferably has a torque of 20 t / m or less, more preferably 10 t / m or less, and even more preferably 7 t / m or less, or preferably has no torque.

[0078] The polymer constituting the core yarn is not particularly limited. The type of 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 cut pile yarn constituting the raised fabric.

[0079] [Method for manufacturing covering yarn] The covering yarn as described above can be manufactured by a method known in the art using a manufacturing apparatus known in the art, for example, as schematically shown in Fig. 12. As an example of such a method, in the case of a single covering yarn, the core yarn fed from a core yarn cheese is passed through a hollow spindle, and the winding yarn is wound around the core yarn at a predetermined covering number by rotating a winding 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 winding yarns, there are a plurality of winding yarn bobbins installed on the hollow spindle, and the same method as the example of the manufacturing method in the case of the single covering yarn described above can be used except that the winding yarn is sequentially wound around the core yarn at a predetermined covering number by rotating them.

[0080] By inputting the fineness of the core yarn and the winding yarn and an arbitrary covering number into the above formula (1), the helix angle θ of the winding yarn can be obtained, and by inputting this into formula (2), the ratio of the length of the winding yarn to the length of the core yarn can be known, so that a covering yarn having a desired ratio of the length of the winding yarn to the length of the core yarn can be manufactured. The above-described fine adjustment of the covering number is required when the set covering number and the actually measured covering number are different. 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.

[0081] (Cut pile fabric manufacturing process) In the cut pile fabric manufacturing process, the covering yarn prepared in the covering yarn preparation process can be used to manufacture a cut pile fabric by a method known in the art using a manufacturing apparatus known in the art, for example, a sinker pile knitting machine, a seal fly knitting machine, a double billow loom, a tricot knitting machine, a raschel knitting machine, and a tufting machine.

[0082] (Pile portion manufacturing process) Next, the covering yarns that constitute the raised parts of the cut pile fabric are unwound. 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. By unwinding the covering yarn in the raised part manufacturing process, for example, a raised part composed of two or more types of cut pile yarns having different raised lengths can be manufactured corresponding to the yarn length difference between the core yarn and the winding yarn.

[0083] When the covering yarn is a double covering yarn, by unwinding both the outer winding yarn and the inner winding yarn of the double covering yarn in the raised part manufacturing process, a raised fabric in which three types of cut pile yarns having different raised lengths stand from the same root can be obtained. In this aspect, it is preferable that the double covering yarn constituting the cut pile fabric has torque in both the inner winding yarn and the outer winding yarn, and each winding yarn is wound around the core yarn in the direction opposite to its own torque. When the double covering yarn has such a configuration, both the inner winding yarn and the outer winding yarn can be easily unwound.

[0084] When the covering yarn is a double covering yarn, by unwinding only the outer winding yarn of the double covering yarn in the raised part manufacturing process, a raised fabric in which two types of cut pile yarns having different raised lengths stand from the same root can be obtained. In this aspect, it is preferable that the double covering yarn constituting the cut pile fabric has torque in both the inner winding yarn and the outer winding yarn, and the inner winding yarn is wound around the core yarn in the same direction as its own torque, and the outer winding yarn is wound around the core yarn in the direction opposite to its own torque. When the double covering yarn has such a configuration, the outer winding yarn can be easily unwound without unwinding the inner winding yarn. Note that the above description is based on the relationship when using the same type of yarn as a principle. That is, the yarn length difference of the cut pile yarn in the finally obtained raised fabric corresponds to the yarn length difference between the core yarn and the wrapping yarn constituting the covering yarn and their unwindability as described above, and can also be controlled by the type of the core yarn and / or the wrapping yarn, etc. For example, when manufacturing a raised fabric by unwinding both the outer wrapping yarn and the inner wrapping yarn of a double covering yarn, depending on the type of the core yarn and / or the wrapping yarn (for example, the difference in shrinkage rate due to heating, etc.), there are cases where a raised fabric having two types of raised hair length differences can be obtained and cases where a raised fabric having three types of raised hair length differences can be obtained.

[0085] The unwinding of the covering yarn can be performed, for example, by pressing a card clothing against the cut pile fabric and moving it in a predetermined direction (combing the fibers). As such a method, a method used for the hair splitting process (opening of fibers) in the manufacture of conventional cut pile fabrics can be adopted. By controlling the penetration depth of the needles into the cut pile fabric, the desired winding of the covering yarn constituting the cut pile yarn can be unwound. The penetration depth of the needles can be appropriately determined according to the configuration of the cut pile fabric to be unwound. However, if the penetration of the needles is too deep, the pile yarn may come out from the ground fabric part during the operation of the hair splitting process. Therefore, in the present invention, the pile yarn up to about 4 mm from the root may not be unwound. Note that there are no particular restrictions on the card clothing to be used, etc., and those used in the conventional hair splitting process can be used. Depending on the conditions during unwinding, the conventional hair splitting process (opening of fibers) can be performed simultaneously. By appropriately selecting the winding direction and the covering number of the covering yarn constituting the cut pile yarn in the raised hair part, the desired winding yarn can be easily unwound. Also, since the covering yarn can be unwound uniformly over the entire desired range, a raised fabric having a uniform texture and excellent appearance can be obtained.

[0086] If necessary, the obtained raised fabric may be subjected to treatments that can be applied to ordinary raised fabrics, such as heat treatment and backing processing. The equipment, processing conditions, etc. used in these processes can be appropriately selected and determined from those used in conventional raised fabrics.

[0087] In the present invention, the cut pile yarns constituting the pile portions of the pile fabric usually exhibit the same physical properties and characteristics (specifically, for example, fineness, breaking strength, crimp elongation rate, and torque) as those in the core yarn or the winding yarn of the covering yarn from which the cut pile yarns are derived. Therefore, the preferred physical properties and characteristics of the cut pile yarns constituting the pile portions in the pile fabric of the present invention are the same as those described above as the physical properties and characteristics of the core yarn or the winding yarn of the covering yarn from which they are derived.

[0088] Since the pile fabric of the present invention forms pile portions with covering yarns and can be manufactured by unraveling them, a long pile length of the cut pile yarns can be easily achieved regardless of the settings of the manufacturing apparatus. In addition, since the difference in pile length of the cut pile yarns can be easily controlled, a long-pile pile fabric having a uniform pile length difference can be efficiently manufactured using a general manufacturing apparatus. For this reason, the pile fabric of the present invention is suitable for applications where long piles and textures, appearances, design properties, etc. due to uniform pile length differences are required. Specific examples of such applications include bedding fabrics such as blankets and towel quilts; wiping fabrics such as cleaning fiber sheets and cleaning mops; clothing fabrics such as artificial furs and jackets; flooring fabrics such as carpets, rugs, and mats; cosmetic fabrics such as puffs; polishing fabrics such as buffs, and the like. Among them, it is particularly suitable as a bedding fabric, a wiping fabric, and a clothing fabric.

Example

[0089] 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 methods for measuring the physical properties of the core yarn, the winding yarn, and the covering yarn will be described below. For the physical properties and measurements (or physical property values and measurement values) described in this specification, including the examples, they are based on the values obtained by the following methods.

[0090] <Breaking strength> For the core yarn and wrapping yarn that make up the covering 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. Also, the breaking strength of the cut pile yarn was regarded as approximately equivalent to the values of the core yarn and wrapping yarn of the covering yarn used as the raw material for each cut pile yarn.

[0091] <Crimp elongation rate> Using a cheese winder, the sample was wound until it became a 5000 denier (d) cheese. 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% without load for one day and night. 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 while the load was 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 while the load was 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

[0092] <Denier> For the core yarn and wrapping 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.

[0093] <Torque> Torque was generated by hanging a 1 g weight at the center of a 1 m long sample and suspending it, 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 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 Z10t / m.

[0094] <Covering number of the winding yarn> Measurement was carried out with reference to "Measurement of the Number of Turns" described in C.10 of JIS L 1095:2010. The gripping interval of the twisting machine was set to 250 mm ± 0.5 mm (i.e., this interval becomes the sample length), and the covering yarn (sample) to be measured was set. 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. One of the non-rotating gripping parts was made movable in the longitudinal direction of the sample so that it could be measured even when it shrank. Also, when the covering yarn is a double covering yarn, after measuring the covering number of the outer winding yarn, the tachometer was turned in the opposite direction to return it to the original position, and then the covering number of the inner winding yarn was measured in the same manner as the covering number of the outer winding yarn. The number of measurements was 5 times, the average value was calculated, and by further converting it to the number of rotations per 1 meter, the covering number of the winding yarn was obtained. 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 Z10t / m.

[0095] <Ratio of the length of the winding yarn to the length of the core yarn and the length of the covering yarn> The covering yarn to be measured was placed on a mount board, and both ends of the sample were fixed to the mount board using cellophane tape so that a tensile tension of 2 cN or more was not applied and the sample length was 200 mm. Next, 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 winding yarn was carefully unwound (in the order of the outer winding yarns when there are multiple winding yarns) so that a tensile tension of 2 cN or more was not applied. For each of the winding 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. Thereafter, the ratio of the length of the winding 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%.

[0096] <Pile height of cut pile yarn (cut pile length)> A 20-cm length was cut out along the warp so that the pile yarn rows of the ground weave generally included three rows when viewed from the back of the plush fabric to be measured, and the lengths of each long and short cut pile yarn included in the range were measured by pressing a scale against the cut pile yarn rows lying horizontally so that the cut pile yarns were not overly stretched. In the measurement, using a scale with a minimum scale of 1.0 mm, the length from the root part to the tip part of each cut pile yarn was visually read to 1 / 10 of the scale. The length of the longest cut pile yarn and the length of the shortest cut pile yarn standing from the same root were measured, and for each set of cut pile yarns standing from the same root, the ratio of the long cut pile yarn to the short cut pile yarn was obtained, and the average value of the ratios of all sets included in the measurement range was taken as the plush length ratio. The coefficient of variation was calculated by calculating the average value and the standard deviation of the yarn lengths of each measured cut pile yarn, and dividing the standard deviation by the average value.

[0097] <Unwinding property> For each cut pile fabric, the unwinding property was evaluated by pressing a card clothing against it and combing the fibers in a predetermined direction. The evaluation criteria for the unwinding property are as follows. A: Can be easily unwound with the normal number of operations B: Even if the card clothing is deeply inserted, the pile shedding is severe and the operation cannot be continued.

[0098] 1. Preparation of covering yarn Table 1 shows the types of yarns used to prepare the covering yarns used in the examples and comparative examples and their physical properties.

[0099] [Table 1]

[0100] Yarns F and G in Table 1 are obtained by cheese-dyeing the raw yarns of yarns E and D, respectively. By cheese-dyeing, the torque is fixed, and a new torque is generated by twisting the yarns that have become substantially non-torque. The new torque is generated in the direction opposite to the twisting direction.

[0101] (1) Preparation of covering yarn 1 As the core yarn, false-twisted yarn B having the characteristics described in Table 1 was prepared. As the inner winding yarn, false-twisted yarn-containing composite yarn E having the characteristics described in Table 1 was prepared. As the outer winding yarn, false-twisted yarn-containing composite yarn C having the characteristics described in Table 1 was prepared. Next, each yarn was installed in a covering yarn manufacturing apparatus, the inner winding yarn was wound around the core yarn in a direction opposite to the torque of the inner winding yarn, and further, the outer winding yarn was wound around in a direction opposite to the torque of the outer winding yarn to prepare a covering yarn. The covering number of the prepared covering yarn and the ratio of the length of the winding yarn to the core yarn were measured.

[0102] (2) Preparation of covering yarns 2 to 10 Except that the types of the core yarn and / or the winding yarns were changed as described in Table 2, each covering yarn was manufactured and evaluated in the same manner as covering yarn 1.

[0103] [Table 2]

[0104] 2. Production of raised fabric (1) Example 1 A double - pile loom was used as the manufacturing apparatus for the plush fabric. Using 20 / 2 polyester spun yarn as the warp and 20 / 1 polyester spun yarn as the weft, with a warp density of 43 threads per inch and a weft density of 40 threads per inch, the pile length (set length) on the loom was set so that a cut - pile fabric with a cut - pile length (before opening) of 15 mm could be obtained on the base fabric, and a cut - pile fabric was obtained using covering yarn 1. The obtained green fabric was subjected to fuzzing processing from the root of the cut - pile yarn by a conventional method, then shirred, and then subjected to backing processing with an acrylic - based resin and hot - air drying at 150 °C for 3 minutes. The opening property, plush length ratio, and coefficient of variation of the covering yarn in the produced plush fabric were evaluated. The results are shown in Table 3.

[0105] (2) Examples 2 - 6 and Comparative Examples 1 - 4 According to the description in Table 3, plush fabrics were produced in the same procedure as in Example 1, except that covering yarn 1 was changed to covering yarns 2 - 10 respectively. In addition, each cut - pile yarn constituting the plush fabrics prepared in Examples 1 - 6 and Comparative Examples 1 - 4 substantially has the physical properties (breaking strength, fineness, crimp elongation rate, torque) of the core yarn or the wrapped yarn of the covering yarn from which it is derived.

[0106]

Table 3

[0107] In Examples 1 - 5, covering yarns were manufactured using undyed wrapped yarns. In Example 6, covering yarns were manufactured using processed yarns that were twist - added after cheese - dyeing. Since the torque of the processed yarn with torque disappears during dyeing, torque in the opposite direction to the twist - adding direction was generated by twist - adding. Also, only in Example 5, single - covering yarn was used. Regarding Example 3, the covering number of the inner - wrapped yarn was set high so that only the outer - wrapped yarn could be opened. In the above examples, cut - pile fabrics with cut - pile heights of approximately two or three types could be obtained. In all examples, the height difference of the cut - pile yarns was uniform in all piles. In contrast, in Comparative Examples 1 to 3, the expected cut pile structure could not be obtained by raising. In Comparative Example 1, the outer winding yarn could not be unwound. For Comparative Example 2, since the winding direction was the same as the total torque, the yarn was tightened by covering, and as a result, the winding yarn could not be unwound. In Comparative Example 3, since no covering yarn was used, a raised hair length longer than the pile length set by machine settings could not be obtained. In this regard, in all of Examples 1 to 6, a raised hair length longer than the pile length set by machine settings could be realized after the covering yarn was unwound. Theoretically, if the ratio of the average length of the longest cut pile yarn after unwinding to the pile length set by machine settings increases, a raised hair fabric having a longer raised hair length can be obtained by setting a shorter knotting yarn length (pile length) when producing a cut pile fabric. Therefore, more stable production can be carried out, which is advantageous in terms of working efficiency and cost. In addition, in Comparative Example 4, although a false-twist yarn was used for the core yarn, an example is shown in which an untreated raw yarn without false twist and without crimp was used as the cut pile yarn with the longest raised hair length. When using raw yarn for cut pile, the covering property is inferior to that of false-twist yarn.

Explanation of symbols

[0108] 1: Raised hair fabric 10: Raised hair part 11: Cut pile yarn with long raised hair length 11-1: Cut pile yarn with the longest raised hair length 11-2: Cut pile yarn with the second-longest raised hair length 12: Cut pile yarn with short raised hair length 13: Covering yarn 14: Root 15: Yarn strand 20: Ground weave part 21: Weft yarn 22: Warp yarn 31: Core yarn 32: Inner winding yarn 33: Outer winding yarn 41: Single covering yarn 42: Core yarn 43: Winding yarn A: End of the winding yarn in the state wound around the core yarn B: End of the winding yarn 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 the right triangle with the line segment A’B’ as the hypotenuse θ1: Helix angle of the winding yarn 44: Representative twill line 45: Straight line drawn along the winding yarn 46: 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 44 and the straight line 45 θ2: Helix angle of the winding 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 winding yarn θ3’: Angle corresponding to the helix angle θ3 of the winding yarn DE: Length corresponding to the distance between D and E EF: Length corresponding to the distance between E and F 47: Double covering yarn 48: Core yarn 49: Inner winding yarn 50: Outer winding yarn 51: Covering yarn manufacturing device 52: Core yarn cheese 53: Hollow spindle for inner winding yarn 54: Hollow spindle belt for inner winding yarn 55: Bobbin for inner winding yarn 56: Balloon guide for inner winding yarn 57: Hollow spindle for outer winding yarn 58: Hollow spindle belt for outer winding yarn 59: Bobbin for outer winding yarn 60: Balloon guide for outer winding yarn 61: Covering yarn package 62: Roller 63: Guide

Claims

1. A raised-pile fabric including a ground fabric portion and a raised-pile portion composed of a plurality of cut pile yarns standing upright and constrained by the ground fabric portion, wherein the raised-pile portion is composed of a plurality of two or more types of cut pile yarns having different raised-pile lengths that stand upright from the same root and are derived from at least partially unravelled one covering yarn, and among the two or more types of cut pile yarns having different raised-pile lengths, at least the cut pile yarn having the longest raised-pile length is a false-twist yarn or a composite yarn including a false-twist yarn, and the ratio of the raised-pile length of the longest cut pile yarn to the raised-pile length of the shortest cut pile yarn among the two or more types of cut pile yarns standing upright from the same root is 1.10 to 1.

90. The raised-pile fabric.

2. The raised-pile fabric according to claim 1, wherein the breaking strength of all the cut pile yarns constituting the raised-pile portion is 2 g / dtex or more.

3. The raised-pile fabric according to claim 1, wherein all the cut pile yarns constituting the raised-pile portion are false-twist yarns or composite yarns including false-twist yarns.

4. The ground fabric portion includes an unravelled covering yarn including a core yarn and one or more winding yarns wound around the periphery thereof, and in the raised-pile portion, two types of cut pile yarns having different raised-pile lengths stand upright from the same root derived from one covering yarn. The raised-pile fabric according to claim 1.

5. The unravelled covering yarn is a double covering yarn, and the two types of cut pile yarns constituting the raised-pile portion are the outer winding yarn of the unravelled double covering yarn and the core yarn covered with the inner winding yarn. The raised-pile fabric according to claim 4.

6. Among the two types of cut pile standing upright from the same root, the cut pile yarn with a longer raised-pile length is the outer winding yarn of the unravelled double covering yarn, and the cut pile yarn with a shorter raised-pile length is the core yarn covered with the inner winding yarn of the unravelled double covering yarn. The raised-pile fabric according to claim 5.

7. The ground fabric portion includes an unravelled covering yarn including a core yarn and two or more winding yarns wound around the periphery thereof, and in the raised-pile portion, three types of cut pile yarns having different raised-pile lengths stand upright from the same root derived from one covering yarn. The raised-pile fabric according to claim 1.

8. The unravelled covering yarn is a double covering yarn, and the three types of cut pile yarns constituting the raised-pile portion are the outer winding yarn, the inner winding yarn and the core yarn of the unravelled double covering yarn. The raised-pile fabric according to claim 7.

9. The raised fabric according to claim 8, wherein in the unopened double covering yarn, the inner winding yarn and the outer winding yarn are wound in opposite directions to each other.

10. The raised fabric according to claim 8, wherein among the three kinds of cut pile standing from the same root, the cut pile yarn with the longest pile length is the outer winding yarn of the double covering yarn from which the cut pile yarn is opened, and the cut pile yarn with the shortest pile length is the core yarn of the double covering yarn from which the cut pile yarn is opened.

11. The raised fabric according to claim 1, which is a fabric for bedding, a wiping fabric, or a clothing fabric.

12. A method for manufacturing the raised fabric according to claim 1, comprising: preparing a covering yarn including a core yarn and one or more winding yarns wound around the core yarn; planting the covering yarn into a base fabric to produce a cut pile fabric including a raised portion composed of the covering yarn; and unwinding the covering yarn constituting the raised portion of the cut pile fabric to produce a raised portion composed of two or more kinds of cut pile yarns having different pile lengths. including: A method, wherein the winding yarn unwound in the step of unwinding the covering yarn is a false twist yarn or a composite yarn including a false twist yarn.

13. The method according to claim 12, wherein the covering yarn is a single covering yarn or a double covering yarn.

14. The method according to claim 12, wherein the covering yarn is a double covering yarn, and in the step of unwinding the covering yarn, both the outer winding yarn and the inner winding yarn of the double covering yarn are unwound.

15. The method according to claim 12, wherein the covering yarn is a double covering yarn, and in the step of unwinding the covering yarn, only the outer winding yarn of the double covering yarn is unwound.

16. The method according to claim 12, wherein the covering yarn is a double covering yarn, the inner winding yarn and the outer winding yarn both have torque, and each winding yarn is wound around the core yarn in a direction opposite to its own torque.

17. The method according to claim 15, wherein the covering yarn is a double covering yarn, the inner winding yarn and the outer winding yarn both have torque, the inner winding yarn is wound around the core yarn in the same direction as its own torque, and the outer winding yarn is wound around the core yarn in a direction opposite to its own torque.

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