Napped fabric for coating tool and method for manufacturing the same

Abstract

To provide a napped fabric for a coating tool which suppresses scattering of a coating material in a coating work, and can provide coating finish excellent in concealment and aesthetics with good workability.SOLUTION: A napped fabric 1 for a coating tool includes a ground weave part 20, and a napped part 10 composed of a plurality of cut pile yarns 11 and 12 which is restrained by the ground weave part and is erected. The napped part includes a plurality of cut pile yarns of two or more kinds which is derived from at least partially released one covering yarn 13, is erected from a shared bottom 14, and has different erection lengths, the cut pile yarn having the longest napping length is a false-twisted yarn having single fiber fineness of less than 1.3 dtex or a composite yarn including a false-twisted yarn. A difference between the napping length of the longest cut pile yarn among the two or more kinds of cut pile yarns erected from the shared bottom and the napping length of the second longest cut pile yarn is 2.0 to 6.0 mm, and a ratio of the longest length to the second longest length is 1.10 to 1.50.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a raised fabric for painters, in particular a raised fabric for painters comprising two or more types of cut pile yarns with different pile lengths derived from unwound covering yarns, a method for producing the same, and a roller-type painter including the raised fabric for painters. [Background technology]

[0002] One known example of a painting tool is a roller-type painting tool commonly known as a paint roller, which has a roller core with fabric wrapped around the outer periphery and fixed to the roller, allowing the roller to rotate. Roller-type painting tools are designed to transfer paint evenly by impregnating a fiber layer with paint and rolling it over the surface to be painted. However, there is a problem in that paint impregnated in the painting tool tends to fly backward as the roller rotates during operation, requiring careful maintenance and the associated costs. To solve this problem, a roller-type painting tool has been proposed that includes a movable hood to capture paint that flies off during operation (Patent Document 1).

[0003] On the other hand, a piled fabric may be used as the fabric wrapped around the roller core material. For example, Patent Document 2 discloses a painting roller having a pile portion made of covering yarns standing up from one side of the base fabric. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2020-185535 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-53068 [Patent Document 3] JP 2003-268652 A [Patent Document 4] JP 2003-138454 A [Patent Document 5] Japanese Patent Application Publication No. 62-104943 [Patent Document 6] JP 2003-306851 A [Patent Document 7] Japanese Patent Application Publication No. 58-018453 Summary of the Invention [Problem to be solved by the invention]

[0005] A roller-type paint sprayer with a movable hood, such as that described in Patent Document 1, does not prevent paint from scattering from the fabric itself, so paint adhering to the hood drips onto the painted surface, and the hood makes it difficult to see the painted surface during painting, which can easily reduce workability. Furthermore, a roller-type paint sprayer using a raised fabric, such as that described in Patent Document 2, has a structure in which the pile portion stands up from the ground weave while maintaining a covering structure to improve the standing ability of the pile portion. In this structure, the pile portion has high rigidity, making it difficult to prevent paint from scattering during painting work.

[0006] Furthermore, napped fabrics themselves are widely used not only for roller-type painters but also for various other purposes such as cleaning wipes, clothing, rugs, etc. For example, Patent Documents 3 to 7 disclose napped fabrics having various configurations, but none of them discloses a configuration that can be satisfactorily applied to roller-type painters.

[0007] An object of the present invention is to provide a raised fabric for painting tools that can suppress paint scattering during painting work and can provide a paint finish that is excellent in hiding power and decorativeness with good workability. [Means for solving the problem]

[0008] The present inventors have conducted extensive research to solve the above problems and have arrived at the present invention. That is, the present invention includes the following preferred embodiments. [1] A piled fabric for a coating tool, comprising a base weave portion and a piled portion made of a plurality of cut pile yarns restrained and erected by the base weave portion, the piled portion is composed of two or more types of cut pile yarns with different pile lengths, which are derived from one covering yarn that has been at least partially unwound and which are raised from the same base, and of which the cut pile yarn with the longest pile length is a false-twisted yarn or a composite yarn comprising a false-twisted yarn having a single fiber fineness of less than 1.3 dtex; the difference between the pile lengths of the longest and second-longest cut pile yarns of the two or more types of cut pile yarns raised from the same base is 2.0 to 6.0 mm; and the ratio of the pile lengths of the longest and shortest cut pile yarns of the two or more types of cut pile yarns raised from the same base is 1.10 to 1.50. [2] The pile fabric for paint tools according to [1], wherein the crimp elongation of the cut pile yarn with the longest pile length is 10% or more. [3] A pile fabric for painters according to [1] or [2], wherein all cut pile yarns constituting the piled portion are false-twisted yarns or composite yarns containing false-twisted yarns. [4] A piled fabric for painters according to any one of [1] to [3], wherein the base weave portion comprises an unreeled covering yarn comprising a core yarn and one or more wrapping yarns wound around the core yarn, and in the piled portion, two types of cut pile yarns with different pile lengths are erected from the same base derived from one covering yarn. [5] A piled fabric for painters according to any one of [1] to [4], wherein the base weave portion includes an unreeled covering yarn comprising a core yarn and two or more wrapping yarns wound around the core yarn, and three types of cut pile yarns with different pile lengths are erected from the same base originating from one covering yarn in the piled portion. [6] The unreeled covering yarn is a double covering yarn, and the three types of cut pile yarns constituting the piled portion are the outer wrapping yarn, inner wrapping yarn and core yarn of the unreeled double covering yarn. [5] A piled fabric for painters. [7] A raised fabric for painters according to [6], wherein the inner and outer wrapping yarns of the unreeled double covering yarn are wound in opposite directions. [8] A pile fabric for painters according to [7], wherein, of three types of cut pile yarns erected from the same base, the cut pile yarn with the longest pile length is the outer wrapping yarn of the unwound double covering yarn, and the cut pile yarn with the shortest pile length is the core yarn of the unwound double covering yarn. [9] A method for producing the raised fabric for painters according to any one of [1] to [8], providing a covering yarn comprising a core yarn and one or more wrapping yarns wound therearound; a step of implanting the covering yarn into a base fabric to produce a cut pile fabric including a raised portion formed from the covering yarn; and a step of unwinding the covering yarn that constitutes the pile portion of the cut pile fabric to produce a pile portion comprising two or more types of cut pile yarns having different pile lengths; Including, The method, wherein the wound yarn unwound in the step of unwinding the covering yarn is a false-twisted yarn or a composite yarn comprising a false-twisted yarn.

[10] The method according to [9], wherein the covering yarn is a single-covering yarn or a double-covering yarn.

[11] The method according to [9] or

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

[12] For a wrapping yarn when the covering yarn is a single covering yarn, or for an inner wrapping yarn when the covering yarn is a double covering yarn, the fineness D1 of the core yarn, the fineness D2 of the wrapping yarn, and the covering number T1 of the wrapping yarn satisfy the following relationship: 330dtex≦total fineness<1550dtex, 70≦T1<500 [Total fineness is D1 + D2] The method according to any one of [9] to

[11] , which satisfies the above.

[13] When the covering yarn is a double-covered yarn, the outer wrapping yarn has a diameter D1 of the core yarn, a diameter D2 of the inner wrapping yarn, a diameter D3 of the outer wrapping yarn, and a covering number T2 of the outer wrapping yarn, which satisfy the following relationship: 50dtex≦total fineness<2000dtex 70≦T2<500 [Total fineness is D1 + D2 + D3] The method according to any one of [9] to

[11] , which satisfies the above.

[14] A roller-type applicator comprising the raised fabric for applicators described in any one of [1] to [8]. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a raised fabric for painting tools that can suppress paint scattering during painting work and can provide a paint finish that is excellent in hiding power and cosmetic appeal with good workability. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram illustrating the structure of the raised fabric for a coating tool of the present invention. [Figure 2] FIG. 2 is a schematic diagram of a raised fabric for a paint tool according to one embodiment of the present invention, viewed from the weft cross section direction. [Figure 3] FIG. 3 is a schematic diagram for explaining the structure of a double-covered yarn. [Figure 4] FIG. 4 is a schematic diagram showing the relationship between the lengths of a core yarn, an inner wrapping yarn, and an outer wrapping yarn in a double-covered yarn. [Figure 5] FIG. 5 is a schematic diagram illustrating the configuration of cut pile constituting a raised fabric for a coating tool according to one embodiment of the present invention, viewed from the weft cross section direction. [Figure 6] FIG. 6 is a schematic diagram illustrating the structure of cut pile constituting a raised fabric for a coating tool according to one embodiment of the present invention, viewed from the weft cross section direction. [Figure 7] FIG. 7 is a diagram for explaining a method for measuring the length of cut pile that constitutes the raised fabric for a coating tool. [Figure 8] FIG. 8 is a diagram for explaining a method for measuring the length of cut pile that constitutes the raised fabric for a coating tool. [Figure 9] FIG. 9 is a schematic diagram showing the arrangement of the core yarn and the wrapping yarn, for explaining the formulas (1) and (2). [Figure 10]FIG. 10 is an enlarged photograph of a covering yarn according to one embodiment of the present invention, used to determine the diameter of the covering yarn and the helix angle of the wrapping yarn around the covering yarn. [Figure 11] FIG. 11 is a schematic diagram for explaining how to determine the helix angle of the wrapping yarn of the covering yarn. [Figure 12] FIG. 12 is a schematic diagram showing an example of a manufacturing apparatus for a covering yarn that can be used in the present invention. [Figure 13] FIG. 13 is a photograph showing the paint finish due to the fiber structure of the pile fabric. [Figure 14] FIG. 14 is a photograph showing the paint scattering during painting work. DETAILED DESCRIPTION OF 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 for painting tools> The piled fabric for painters of the present invention (hereinafter simply referred to as "pile fabric") comprises a base weave portion and a piled portion composed of a plurality of cut pile yarns that are restrained by the base weave portion and stand upright. The piled portion is composed of a plurality of cut pile yarns of two or more types with different pile lengths that are derived from one covering yarn that has been at least partially unwound and that stand upright from the same base.

[0013] For example, the piled fabric 1 shown in Figure 1 is composed of a piled portion 10 formed from cut pile yarns 11 with a long pile length and cut pile yarns 12 with a shorter pile length than the cut pile yarns 11, and a ground weave portion 20 formed from weft yarns 21 and warp yarns 22. In this disclosure, the ground weave portion refers to the basic components assembled according to a certain rule so that a woven or knitted fabric can form a sheet-like body. In the case of a woven fabric, for example, it refers to the state in which weft yarns and warp yarns are combined according to a certain rule. In the ground weave portion 20, covering yarns 13 are regularly bound by weft yarns 21 and warp yarns 22. The cut pile yarns 11 and 12 that make up the piled portion 10 each originate from a single covering yarn 13, and extend from the same root 14 through the ground weave portion 20 to stand on the surface of the fabric.

[0014] In this disclosure, "standing" refers to the state in which cut pile yarns penetrate the ground weave portion surrounded by warp and weft yarns and appear on the surface of the fabric. Furthermore, "root" refers to the portion where the cut pile yarns penetrate the ground weave portion on the side where they are standing. "Originating from one covering yarn" means that when one end of the cut pile is pulled out from the ground weave portion, the cut pile yarn is derived from the same covering yarn. "Two or more types of cut pile yarns" here means that there are two or more cut pile yarns with different lengths (raising lengths). In other words, the piled portion of the present invention has two or more stages of difference in rising length due to the presence of the two or more types of cut pile.

[0015] FIG. 2 is a view of the piled fabric 1 shown in FIG. 1, viewed from the cross-sectional direction of the weft yarn 21. Two types of cut pile yarns with different pile lengths, i.e., cut pile yarns 11 and 12, originating from a single covering yarn 13, are erected from the same root 14 through the ground weave portion 20. The piled portion 10 includes multiple roots 14, and a pair of cut pile yarns 11 and 12 is erected from each of the multiple roots 14. Two or more types of cut pile yarns with different pile lengths are obtained by unwinding the wrapped yarn of the covering yarn from which the cut pile yarns are derived. In the piled fabric of the present invention, typically, two or more cut pile yarns of different lengths are present at one or both ends of a single covering yarn. A plurality of such covering yarns are confined in the ground weave portion, and the piled portion is composed of multiple cut pile yarns derived from each covering yarn. In FIG. 2, cut pile yarn 11 with a long pile length originates from the wrapped yarn of covering yarn 13, and cut pile yarn 12 with a short pile length originates from the core yarn of covering yarn 13, and is obtained by unwinding covering yarn 13 from its root 14.

[0016] In a piled fabric, each covering yarn is typically restrained in two or more places in the ground weave portion, and when viewed in the weft cross section, it can be restrained in the shape of the letters U, V, or W. For example, in Figure 2, it is restrained in a W shape. In either case, one covering yarn is unwound at both ends that penetrate the ground weave portion, forming two or more cut pile yarns. Therefore, each covering yarn restrained in the ground weave portion typically has roots at both ends where the cut pile yarns will stand. In other words, each covering yarn restrained in the ground weave portion typically has two roots where the cut pile yarns will stand.

[0017] Conventionally, covering yarns have been used in a variety of applications due to the advantages of their structure in which a core yarn is covered by a sheath yarn, and even in piled fabrics using covering yarns, it has not been assumed that the covering yarns will be unwound and used (for example, Patent Documents 2 and 6). On the other hand, the present invention provides a piled fabric for painters with an unprecedented structure, having a piled portion formed from cut pile derived from the unwound covering yarn, based on the relationship that the length of the wrapping yarn that constitutes the covering yarn is always longer than the length of the core yarn. Pile fabrics can be produced from various fibers depending on the application using weaving and knitting machines such as sinker pile knitting machines, double velvet looms, and tufting machines. The pile length of the pile fabrics produced using such machines is generally determined by the components (e.g., sinkers, loopers, etc.) of the machine used and the conditions set for that machine. However, in the pile fabric of the present invention, by previously controlling the lengths of the core yarn and wrapping yarn in the covering yarn used to the desired lengths, pile fabrics with a variety of different pile lengths can be efficiently produced without the need for special machines or changing machine settings. In particular, because the pile length of the cut pile yarn can be controlled to the desired length by adjusting the length of the wrapping yarn, a pile length exceeding the cut pile height determined by the machine settings can be achieved. Furthermore, because the pile length can be controlled by the length of the wrapping yarn, compared to conventional techniques, by setting the binding yarn length (pile length) short when producing a cut pile fabric, it is advantageous in terms of work efficiency and cost, and by unwinding the covering yarn, it is possible to more easily obtain a piled fabric with a high pile height. Furthermore, because the final pile length can be controlled at the covering yarn stage used in fabric production, it is possible to more easily achieve a uniform pile length difference throughout the entire target area compared to methods (e.g., Patent Documents 4 and 5) that use differential shrinkage of fibers due to heat treatment or solvent treatment after fabric formation to produce a difference in pile length.

[0018] The number of cut pile yarns erected from one base in the piled portion can be adjusted by the number of wrapping yarns of the covering yarn used to form the piled portion and the number of those yarns to be unwound. For example, in a double-covered yarn 30 in which an inner wrapping yarn 32 and an outer wrapping yarn 33 are wound around a core yarn 31 as shown in Figure 3, when the two wrapping yarns are unwound, three cut pile yarns emerge from the same base, as shown in Figure 4. When only the outer wrapping yarn of a double-covered yarn is unwound, two cut pile yarns emerge from the same base. Furthermore, when a single-covered yarn in which one wrapping yarn is wound around a core yarn is used, a piled fabric in which two yarns erected from the same base can be obtained.

[0019] The pile length of the cut pile yarn, which stands up from one base in the piled portion, depends on the lengths of the core yarn and the wrapping yarn of the covering yarn used to form the piled portion. Because the wrapping yarn is wrapped around the core yarn, when the wrapping yarn is unwound, its length becomes longer than that of the core yarn, as shown in Figure 4. That is, for example, if the covering yarn is a single covering yarn, a two-stage difference in yarn length (the difference between the length of the core yarn and the length of the wrapping yarn) will occur after the wrapping yarn is unwound, as shown in Figure 5. Similarly, if the covering yarn is a double covering yarn, for example, and only the outer wrapping yarn is unwound, a two-stage difference in yarn length (the difference between the length of the core yarn and the length of the outer wrapping yarn) will occur after the outer wrapping yarn is unwound. Furthermore, for example, when the covering yarn is a double-covering yarn, if all the wrapping yarns are unwound, three-stage yarn length differences (differences in length between the core yarn, the inner wrapping yarn, and the outer wrapping yarn) will occur as shown in Figure 6. Due to the occurrence of such yarn length differences resulting from the covering yarns used, the piled fabric of the present invention can achieve a pile length that is sufficiently longer than the cut pile height determined by the machine settings.

[0020] In the piled fabric of the present invention, of two or more types of cut pile yarns erected from the same base, the cut pile yarn with the longest pile length has a single fiber fineness of less than 1.3 dtex. By using a yarn having a single fiber fineness of less than 1.3 dtex as the cut pile yarn with the longest pile length (hereinafter also referred to as "fine fiber"), paint splatter during painting can be reduced. Furthermore, the presence of fine fiber on the outermost surface of the piled fabric allows for a paint finish with excellent decorative properties. In one embodiment of the present invention, the single fiber fineness of the cut pile yarn with the longest pile length is preferably 0.05 dtex or more but less than 1.3 dtex, more preferably 0.1 dtex or more but 1.2 dtex or less. When the single fiber fineness of the cut pile yarn with the longest pile length is within the above-mentioned range, the above-mentioned effects can be further enhanced. The single fiber fineness of the cut pile yarn can be measured in accordance with JIS L 1013:2021.

[0021] In the piled fabric of the present invention, of two or more types of cut pile yarns erected from the same base, the cut pile yarns other than the cut pile yarn with the longest pile length preferably have a single fiber fineness of 1.3 dtex or more, more preferably 1.5 dtex or more, even more preferably 2.0 dtex or more, and particularly preferably 2.5 dtex or more. For example, cut pile yarns with a single fiber fineness of 3.0 dtex or more may be included. By having the single fiber fineness of the cut pile yarns other than the cut pile yarn with the longest pile length greater than that of the finer cut pile yarn with the longest pile length, only finer fibers can be present on the outermost surface of the piled fabric. While the use of finer fibers ensures scattering suppression and a good paint finish, the presence of cut pile yarns with thicker single fiber finenesses around them suppresses pile collapse of the cut pile yarns and increases the hiding power of the thicker paint film. Furthermore, shrinkage of the fiber layer, including the piled portion, can be suppressed, which is advantageous in terms of improving paint work efficiency. In one embodiment of the present invention, the single fiber fineness of the cut pile yarns other than the cut pile yarn with the longest pile length is preferably 1.5 dtex to 12 dtex, more preferably 2.0 dtex to 10 dtex, and even more preferably 2.5 dtex to 8 dtex. When the single fiber fineness of the cut pile yarns other than the cut pile yarn with the longest pile length is within the above range, the above-mentioned effects can be further enhanced.

[0022] In the piled fabric of the present invention, 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 erected from the same base (pile length of longest cut pile yarn / pile length of shortest cut pile yarn) is 1.10 to 1.50, preferably 1.15 to 1.45, and more preferably 1.20 to 1.40. When the pile length ratio is equal to or greater than the lower limit, an appropriate difference in pile length between the cut pile yarns in the piled portion can be ensured. When the ratio is equal to or less than the upper limit, a sufficient difference in pile length can be ensured without causing pile collapse. Another advantage is that the number of coverings in the covering yarn is reduced, leading to stable unwinding.

[0023] The ratio of the pile lengths is calculated by measuring the pile lengths of the longest and shortest cut pile yarns among two or more types of cut pile yarns erected from the same base, and then calculating the ratio. In this specification, the pile length of the cut pile yarn refers to the length from the surface of the ground weave on the side where the cut pile yarn is erected to the tip of the cut pile yarn. For example, as shown in Figure 7, a 20 cm length is cut out along the warp to include approximately three rows of pile yarns in the ground weave when viewed from the back of the piled fabric, and the lengths of the long and short cut pile yarns within this range are measured using, for example, a ruler or measuring stick. To avoid excessive stretching of the cut pile yarns, the cut row of cut pile yarns is laid on its side and pressed against the ruler, as shown in Figure 8. In the measurements shown in Figure 8, a ruler with a minimum scale of 1.0 mm was used, and the length from the base of each cut pile yarn to its tip was visually read to 1 / 10 of the scale. The scale of the ruler used for the measurement can be selected appropriately depending on the length of the cut pile yarn being measured. For each measured cut pile yarn length, the ratio of the pile length for each set of cut pile yarns erected from the same base was calculated, and the average of the ratios for all sets within the range being measured can be used to determine the pile length ratio in this invention. More specifically, the measurement can be performed according to the method described in the Examples below.

[0024] In the piled fabric of the present invention, among two or more types of cut pile yarns erected from the same base, the difference in the pile length between the longest cut pile yarn and the second longest cut pile yarn is 2.0 to 6.0 mm. Using fine fibers in the piled portion of the piled fabric can prevent paint from scattering during painting and improve the aesthetic appeal of the painted finish, but the resulting paint film may not be thick enough to ensure high hiding power. Furthermore, if the pile length of the fine fibers is long, the fiber layer formed by these fibers is likely to shrink, reducing the paint absorption and reducing work efficiency. In the piled fabric of the present invention, by keeping the difference between the pile length of the longest cut pile yarn and the pile length of the second longest cut pile yarn below the above-mentioned upper limit, pile collapse is less likely to occur, and a piled fabric using fine fibers as the cut pile yarn with the longest pile length can obtain a coating film of sufficient thickness and improve hiding power. Furthermore, shrinkage of the fiber layer can be effectively suppressed. In one embodiment of the present invention, the difference in nap length is preferably 2.0 to 5.5 mm, more preferably 2.0 to 5.0 mm, and may be, for example, 2.0 to 4.5 mm, or 2.5 to 4.0 mm. When the difference in nap length is within the above range, the effect can be further enhanced.

[0025] The difference in pile length is calculated by measuring the pile length of the longest cut pile yarn and the pile length of the second longest cut pile yarn among two or more types of cut pile yarns erected from the same base, and then calculating the difference between these measurements. Specifically, the pile lengths of the cut pile yarns are measured according to the method described above, and the difference in pile length is calculated for each set of cut pile yarns erected from the same base. The difference in pile length in this invention can be determined as the average of the differences for all sets within the measurement range. More specifically, it can be measured according to the method described in the Examples below.

[0026] In the piled fabric of the present invention, in which the difference in pile length of the cut pile yarns is realized by unwinding the covering yarn, the difference in pile length can be controlled by the design of the covering yarn, thereby minimizing the variation in the difference in pile length between the short and long cut pile yarns between each base (hereinafter simply referred to as "variation in pile length difference"). Therefore, in the piled fabric of the present invention, a uniform difference in pile length can be achieved throughout the target area more easily than in a method of achieving a difference in pile length by utilizing the difference in fiber shrinkage caused by heat treatment or solvent treatment after fabric formation. In the piled fabric of the present invention, it is preferable that cut piles with a uniform difference in pile length between long and short are erected from almost all bases where the cut piles are erected. Little or no variation in the difference in pile length results in a piled fabric with excellent texture and appearance. The variation in the difference in pile length can be evaluated, for example, using the coefficient of variation of the ratio between the pile length of the longest cut pile yarn and the pile length of the shortest cut pile yarn among two or more types of cut pile yarns erected from the same base as an index. The smaller the coefficient of variation, the more uniform the difference in pile length.

[0027] The coefficient of variation can be calculated, for example, as follows: A given measurement range is cut out from the piled fabric, and the length of each cut pile yarn within the range is measured in the same manner as in the measurement of the ratio of the pile lengths of the longest and shortest cut pile yarns at the same base, and the ratio of the pile lengths for each set of cut pile yarns erected from the same base is calculated, and the coefficient of variation is determined based on the average value and standard deviation of the entire measurement range.

[0028] In the piled fabric of the present invention, of the two or more cut pile yarns with different pile lengths, at least the cut pile yarn with the longest pile length is or comprises a false-twisted yarn or a composite yarn containing a false-twisted yarn (hereinafter also referred to as a "false-twisted-yarn-containing composite yarn"). Preferably, substantially all of the cut pile yarns constituting the piled portion are or comprise a false-twisted yarn or a false-twisted-yarn-containing composite yarn. In this disclosure, "false-twisted yarn" refers to a false-twisted yarn commonly used in the art, i.e., a textured yarn produced by the false-twisting method. In this disclosure, "false-twisted-yarn-containing composite yarn" refers to a yarn obtained by combining the false-twisted yarn with a false-twisted yarn or raw silk by fluid entanglement. Examples of such composite yarns include interlaced yarn and taslan yarn. Depending on the false-twisting conditions, false-twisted yarns range from non-bulky false-twisted yarns with little bulk to highly crimped false-twisted yarns with high bulk. In the present invention, the false-twisted yarn or false-twisted-yarn-containing composite yarn constituting the cut pile yarn in the piled portion preferably has bulkiness (i.e., is not non-bulky) from the viewpoints of improving paint uptake when used as a painting tool due to the volume of the cut pile yarn constituting the piled portion and of ease of unwinding from the covering yarn during the production of piled fabric. In this disclosure, a "bulky" false-twisted yarn or false-twisted-yarn-containing composite yarn means, for example, one having a crimp elongation of 10% or more. In one embodiment of the present invention, the false-twisted yarn or false-twisted-yarn-containing composite yarn preferably has a crimp elongation of 12% or more, more preferably 15% or more, and even more preferably 20% or more. In particular, it is preferable that the cut pile yarn with the longest pile length has a crimp elongation of 10% or more. While there is no particular upper limit for the crimp elongation of the cut pile yarn, from the viewpoints of handleability and workability, it is usually 60% or less, preferably 40% or less. The crimp elongation can be adjusted to be equal to or greater than the lower limit or equal to or less than the upper limit by selecting the false twist conditions for the yarn. The crimp elongation can be measured, for example, by the same method as that for measuring the crimp elongation of the covering yarn in the examples described below. The crimp elongation of the cut pile yarn in the present invention may be measured for the cut pile yarn that constitutes the piled fabric, or may be measured as the crimp elongation of the covering yarn that is the constituent material of the piled fabric.Hereinafter, if there is no substantial change in the physical properties of the covering yarn that is the constituent material of the piled fabric, the physical properties of the covering yarn used can be considered to be the physical properties of the cut pile yarn of the piled fabric.

[0029] False-twisted yarns can have no torque, low torque, or high torque, depending on the number of false twists set in the false-twisting method. Furthermore, non-torque false-twisted yarns can be produced by simultaneously winding two false-twisted yarns with opposite twist directions during twisting and heat setting, or by dyeing the false-twisted yarn to fix the original torque of the false-twisted yarn. As described above, the piled fabric of the present invention is composed of multiple cut pile yarns derived from an unwound covering yarn. By selecting the torque and winding direction of the wrapping yarns that make up this covering yarn, the unwinding properties of the covering yarn can be controlled, resulting in piled fabrics with various types of napped portions, as described below. In one embodiment of the present invention, the cut pile yarn (false-twisted yarn or false-twisted-yarn-containing composite yarn) with the longest pile length, derived from the outermost wrapping yarn of the covering yarn, preferably has torque. Furthermore, even if a false-twisted yarn is dyed and non-torque, by further twisting it and selecting the direction of the twist and the winding direction of the covered yarn, the unwinding properties of the covered yarn can be controlled in the same way as when a false-twisted yarn with torque is used. Therefore, when using a dyed false-twisted yarn, it is preferable to use a false-twisted yarn. The further twisting can be carried out by a conventionally known method.

[0030] In the piled fabric of the present invention, of the two or more cut pile yarns with different pile lengths, the cut pile yarns other than the cut pile yarn with the longest pile length may be, for example, spun yarn, false twisted yarn, or false twisted yarn-containing composite yarn. From the viewpoint of the standability of the cut pile yarn and the volume of the piled portion, it is preferable that substantially all of the cut pile yarns constituting the piled portion are or contain false twisted yarn or false twisted yarn-containing composite yarn. In this case, the crimp elongation and the presence or absence of torque of the false twisted yarn or false twisted yarn-containing composite yarn are not particularly limited, but the same embodiments as those for the outer wrapping yarn described above can be applied.

[0031] In the piled fabric of the present invention, the breaking strength of all cut pile yarns constituting the piled portion is preferably 2 g / dtex or more. A cutting pile yarn breaking strength of 2 cN / dtex or more can prevent some of the fibers constituting the cut pile yarn from falling off when the covering yarn is unwound and / or the cut pile yarn is opened. A cutting pile yarn breaking strength equal to or greater than the above limit can prevent a decrease in the density of the piled portion due to fiber fall-off, ensure sufficient paint absorption, prevent fluff from falling off onto the painted surface, and provide a highly aesthetically pleasing painted finish. To prevent fiber fall-off, the breaking strength of the cut pile yarn is preferably 2.1 cN / dtex or more, more preferably 2.5 cN / dtex or more, even more preferably 3.0 cN / dtex or more, and particularly preferably 3.3 cN / dtex or more. While there is no particular upper limit for the breaking strength of the cut pile yarn, it is typically 7.0 cN / dtex or less. The breaking strength of cut pile yarn can be measured in accordance with JIS L 1013:2021. The breaking strength of cut pile yarn is usually not significantly lower than the breaking strength of the core yarn and wrapping yarn of the covering yarn used. Therefore, for example, by using a covered yarn composed of a core yarn and wrapping yarn with a breaking strength of more than 2 cN / dtex as the material, the breaking strength of the cut pile yarn in a piled fabric can usually be made 2 cN / dtex or more. In this disclosure, unwinding refers to unwinding the wrapping yarn of the covering yarn from the core yarn (generally an action that acts on a fiber bundle), and opening refers to opening the fibers of the cut pile yarn with card clothing or the like to give texture and volume in the finishing process of piled fabric, for example (also known as pile splitting, generally an action that separates the constituent fibers into single yarns), regardless of whether the cut pile yarn is derived from the covering yarn or not. Therefore, depending on the processing method, unwinding and opening may be performed simultaneously.

[0032] The polymers constituting the cut pile yarns constituting the piled portion can be appropriately selected depending on the intended use of the piled fabric. Examples of such polymers include aromatic polyesters such as polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate; aliphatic polyesters such as polylactic acid and polyglycolic acid; polyesters obtained by copolymerizing these polyesters with a third component (e.g., isophthalic acid and / or 5-sodium sulfoisophthalic acid); polymers obtained by kneading these polyesters with functional agents (e.g., deodorants and / or flame retardants); aliphatic polyamides such as nylon 6, nylon 66, and nylon 610; polyolefins such as polystyrene, polyvinyl chloride, and polyvinylidene chloride; and acrylic or acrylic polymers. Each cut pile yarn may be composed of one type of polymer or two or more types of polymers, such as a core-sheath type, a split type, or an island-in-sea type. Among the polymers listed above, polyethylene terephthalate, nylon 66, and polystyrene are preferred from the viewpoint of crimp development after false twisting, with polyethylene terephthalate and nylon 66 being more preferred.

[0033] The cross-sectional shape of the cut pile yarns constituting the piled portion is not particularly limited, and may be, for example, a round cross-section, a flat cross-section, a multi-branch cross-section, or a mixture of irregular cross-sections.

[0034] The pile length of each cut pile yarn constituting the piled portion can be determined appropriately depending on the intended use of the piled fabric, the product grade, etc. The pile length of each cut pile yarn is determined so that the ratio between the pile length of the longest cut pile yarn and the pile length of the shortest cut pile yarn among those raised from the same base, and the difference between the pile length of the longest cut pile yarn and the pile length of the second longest cut pile yarn among those raised from the same base, fall within the ranges described above. For example, the pile length of the longest cut pile yarn among the multiple types of cut pile yarns constituting the piled portion may be, for example, 10 to 35 mm, preferably 15 to 30 mm. The pile length of the shortest cut pile yarn among the multiple types of cut pile yarns constituting the piled portion may be, for example, 5 to 25 mm, preferably 10 to 20 mm. The pile length of each cut pile yarn can be measured according to the method described above for measuring the pile length ratio of cut pile yarns.

[0035] In one embodiment of the present invention (hereinafter also referred to as the "first embodiment"), the ground structure portion comprises an unreeled covering yarn comprising a core yarn and one or more wrapping yarns wound around it, and in the piled portion, two cut pile yarns of different pile lengths originating from one covering yarn are erected from the same base. Figure 5 is a schematic diagram of a single yarn constituting the piled fabric of the present invention in the first embodiment, viewed from the cross-sectional direction of the weft, having a pair of cut pile yarns of different pile lengths at both ends. In Figure 5, yarn 15 is restrained by weft yarn 21 to form ground structure portion 20, and both ends of yarn 15 penetrate ground structure portion 20, with a pair of cut pile yarns 11 and 12 of different pile lengths erected from the same base. In the first embodiment, the portion of the yarn 15 that is restrained by the ground structure portion 20 exists as a covering yarn 13 in a state where one or more wrapping yarns are wound around a core yarn (i.e., in an unreeled state). On the other hand, in the piled portion 10, the covering yarn is unreeled and exists as cut pile yarns 11 and 12.

[0036] In the first embodiment, the unreeled covering yarn 13 may be, for example, a double-covered yarn. In this case, the unreeled covering yarn 13 is composed of a core yarn and two wrapping yarns wrapped around it, and the two types of cut pile yarns 11 and 12 constituting the piled portion 10 in Fig. 5 are derived from the outer wrapping yarn of the unreeled double-covered yarn and the core yarn covered with the inner wrapping yarn, respectively. This embodiment (hereinafter also referred to as "embodiment 1-1") can be achieved by unreeling only the outer wrapping yarn of the double-covered yarn. Of the two types of cut piles 11 and 12 erected from the same base 14 in the piled fabric of this embodiment, the cut pile yarn 11 with the longer pile length is derived from the core yarn in which the outer wrapping yarn of the unreeled double-covered yarn is covered, and the cut pile yarn 12 with the shorter pile length is derived from the core yarn in which the inner wrapping yarn is covered.

[0037] In the first embodiment, the unreeled covering yarn 13 may be, for example, a single covering yarn. In this case, the unreeled covering yarn 13 is composed of a core yarn and a single wrapping yarn wound around it, and the two types of cut pile yarns 11 and 12 that make up the piled portion 10 in Fig. 5 are derived from the wrapping yarn of the unreeled single covering yarn and the core yarn of the single covering yarn, respectively. This embodiment (hereinafter also referred to as "embodiment 1-2") can be achieved by unreeling a single covering yarn, and of the two types of cut piles 11 and 12 that stand up from the same base 14 in the piled fabric of this embodiment, the cut pile yarn 11 with a longer pile length is derived from the wrapping yarn of the unreeled single covering yarn, and the cut pile yarn 12 with a shorter pile length is derived from the core yarn.

[0038] In another embodiment of the present invention (hereinafter also referred to as the "second embodiment"), the ground structure portion comprises an unreeled covering yarn comprising a core yarn and two or more wrapping yarns wound around it, and in the piled portion, three cut pile yarns of different pile lengths are erected from the same base derived from one covering yarn. Figure 6 is a schematic diagram of a single yarn constituting the piled fabric of the present invention in the second embodiment, viewed from the cross-sectional direction of the weft, having a pair of cut pile yarns of different pile lengths at both ends. In Figure 6, yarn 15 is restrained by weft 21 to form ground structure portion 20, and both ends of yarn 15 penetrate ground structure portion 20, with a pair of cut pile yarns 11-1, 11-2, and 12 of different pile lengths erected from the same base. In the second embodiment, the portion of the yarn 15 that is restrained by the ground structure portion 20 exists as a covering yarn 13 in a state where two or more wrapping yarns are wound around a core yarn (i.e., in an unreeled state). On the other hand, in the piled portion 10, the covering yarn is unreeled and exists as cut pile yarns 11-1, 11-2, and 12.

[0039] In the second embodiment, the unreeled covering yarn 13 is preferably a double-covered yarn. In this case, the unreeled covering yarn 13 is composed of a core yarn and two wrapping yarns wrapped around it, and the three types of cut pile yarns 11-1, 11-2, and 12 that make up the piled portion 10 are derived from the outer wrapping yarn, inner wrapping yarn, and core yarn of the unreeled double-covered yarn, respectively. This embodiment (hereinafter also referred to as "embodiment 2") can be achieved by unreeling a double-covered yarn. Of the three types of cut piles 11-1, 11-2, and 12 that are erected from the same base 14 in the piled fabric of this embodiment, the cut pile yarn 11-1 with the longest pile length is derived from the outer wrapping yarn of the unreeled double-covered yarn, the cut pile yarn 11-2 with the second longest pile length is derived from the inner wrapping yarn, and the cut pile yarn 12 with the shortest pile length is derived from the core yarn. In addition, in the unreeled covering yarn 13, it is preferable that the inner wrapping yarn and the outer wrapping yarn are wound in opposite directions.

[0040] <Method for manufacturing pile fabric> The piled fabric of the present invention is, for example, A step of preparing a covering yarn comprising a core yarn and one or more wrapping yarns wound around the core yarn (hereinafter also referred to as a "covering yarn preparation step"); a step of implanting the covering yarn into a base fabric to produce a cut pile fabric including a pile portion formed from the covering yarn (hereinafter also referred to as a "cut pile fabric production step"); and A step of unwinding the covering yarn that constitutes the pile portion of the cut pile fabric to produce a pile portion composed of two or more types of cut pile yarns with different pile lengths (hereinafter also referred to as the "pile portion production step"). The method can be prepared by a method comprising:

[0041] (Covering thread preparation process) The piled fabric of the present invention can be produced using a covering yarn that includes a core yarn and one or more wrapping yarns wound around it, with at least the outermost wrapping yarn being unwindable. By unwinding the wrapping yarn of the covering yarn, the piled fabric of the present invention can be formed, in which two or more cut pile yarns standing from the same base are erected. The covering yarn used in the present invention can be produced from conventionally known materials and by conventionally known methods, as long as the two or more cut pile yarns standing from the same base have the above-mentioned pile length ratio when unwound after fabric formation. For example, by appropriately selecting the configuration of the covering yarn, such as the fineness of the constituent fibers, the number of coverings, and the winding direction of the wrapping yarn, the unwindability of the covering yarn can be controlled to produce a piled fabric with the desired pile configuration. Note that in the covering yarn that can be used to produce the piled fabric of the present invention, the core yarn does not necessarily need to be completely covered by the wrapping yarn. This is because the purpose of the conventional covering yarn, such as protecting the core yarn, does not exist in the present invention.

[0042] In the covering yarn used to produce the piled fabric of the present invention, the ratio of the length of the outermost wrapping yarn to the length of the core yarn is preferably 1.10 to 1.50. When the length ratio of the core yarn to the outer wrapping yarn in the covering yarn is within this range, 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 erected from the same base after the wrapping yarn is unwound can be controlled within the specified range. This is also advantageous in terms of facilitating unwinding of the covering yarn. The ratio can be determined appropriately depending on the pile length of the cut pile yarn in the final desired piled fabric. From the viewpoints of ease of unwinding the wrapping yarn and of making it easier to obtain a piled fabric with a sufficient pile length difference, the ratio is more preferably 1.10 to 1.50, even more preferably 1.15 to 1.45, and particularly preferably 1.20 to 1.40.

[0043] The length ratio of the core yarn and the wrapping yarn that make up the covering yarn is calculated by measuring the lengths of the core yarn and the wrapping yarn of one covering yarn, respectively. The lengths of the core yarn and the wrapping yarn in the covering yarn can be measured, for example, by cutting the covering yarn to be measured to a predetermined length, unwinding the covering yarn so as not to apply excessive tension, and applying a certain tension (for example, a tensile tension of 2 cN or less) to the yarn to be measured. In detail, the measurement can be performed according to the method described in the Examples below.

[0044] The ratio of the length of the wrapping yarn to the length of the core yarn can be adjusted, for example, by appropriately selecting the fineness of the core yarn, the fineness of the wrapping yarn, and the number of coverings of the wrapping yarn (the number of turns of the wrapping yarn per meter of covering yarn). An example of a method for adjusting the ratio will be described using the case of producing a single-covered yarn as an example. FIG. 9 shows a schematic diagram illustrating the arrangement of a core yarn 42 and a wrapping yarn 43. The left side of FIG. 9 is a schematic cross-sectional view of a single-covered yarn 41 cut perpendicular to its longitudinal direction. The center of FIG. 9 is a schematic diagram of a wrapping yarn 43 (ends A and B) wound once around the core yarn 42 at a helix angle θ1 (radians), and the right side of FIG. 9 is a schematic diagram of the wrapping yarn before the wrapping yarn 43 (ends A' and B') is wound around the core yarn 42 at the helix angle θ1. Note that in FIG. 9 and FIGS. 11 and 12 (described later), the dimensions and ratios of the components have been appropriately changed to make the drawings easier to understand. The line segment A'C corresponds to (diameter of the winding yarn 43 + diameter of the core yarn 42 + 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), so tan θ1 is expressed by the following formula. tan θ1=(1 / T) / {(diameter of the winding yarn 43+diameter of the core yarn 42+diameter of the winding yarn 43)×π} When the core yarn and wrapping yarn are polyester, the relationship between the polyester fineness and diameter d is generally expressed by the following formula, where 1.38 is used as the specific gravity of polyester. d[μm]=10×(fineness) 1 / 2 In this case, the fineness of the core yarn is D1 (denier), the fineness of the wrapping yarn is D2 (denier), and the number of coverings of the wrapping yarn is T x 10 -6 When the thickness is (t / μm), tan θ1 is expressed by the following formula (1). tanθ1=1 / {T×10 -6 ×(10×D2 1 / 2 +10×D1 1 / 2 +10×D2 1 / 2 )×π} =1 / {10 -5 ×π×T×(D1 1 / 2 +2×D2 1 / 2 )} Formula (1) When the core yarn or wrapping yarn is nylon (specific gravity: 1.14) or olefin (specific gravity: 0.91 to 0.98), the relationship between the fineness and the diameter d is roughly expressed by the following formula: d [μm] = 11 × (fineness)1 / 2 Or d [μm] = 12 × (fineness) 1 / 2 Therefore, if the core yarn or wrapping yarn is nylon or olefin, these formulas can be expressed as d [μm] = 10 × (fineness) 1 / 2 Even when the core yarn or the wrapping yarn is made of a material other than polyester, nylon, or olefin, the above-mentioned relationship between the fineness and the diameter d is publicly known (for example, as described in the Fiber Handbook compiled by the Fiber Society of Japan), and therefore, this relationship can be applied to the above formula. As is clear from the diagram on the right side of FIG. 9, the ratio of the length of the wrapping yarn 43 to the length of the core yarn 42 is expressed by the following formula. Ratio of the length of the wrapping 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 can be seen that the ratio of the length of the wrapping yarn to the length of the core yarn can be adjusted by the fineness of the core yarn, the fineness of the wrapping yarn, and / or the number of coverings of the wrapping yarn.

[0045] In the left diagram of Figure 9, the core yarn 42 and the wrapping yarn 43 are assumed to be cylindrical and not deformed. However, in reality, the core yarn 42 and the wrapping yarn 43 are usually deformed to some extent from a cylindrical shape. Furthermore, in the center and right diagrams of Figure 9, the diameter of the wrapping yarn 43 is not taken into account. However, it was confirmed that the tan θ or yarn length ratio calculated using Equation (1) and Equation (2) was in good agreement with the tan θ or yarn length ratio actually measured from the manufactured covered yarn. Therefore, Equation (1) and Equation (2) can be used to determine the covering number or helix angle of the wrapping yarn to obtain a desired yarn length ratio.

[0046] Generally, fabrics are often heat-treated (for example, at a temperature of 100 to 180°C, e.g., about 150°C) after knitting and weaving to develop the bulkiness of the yarns used. When knitting and weaving the piled fabric of the present invention, it is also preferable to heat-treat the fabric after knitting and weaving. Therefore, by determining the ratio of the length of the wrapping yarn to the length of the core yarn in the covering yarn after such heat treatment, it may be possible to evaluate a 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 in the actual piled fabric. The ratio of the length of the wrapping yarn to the length of the core yarn in the covering yarn after heat treatment tends to be smaller than the ratio in the covering yarn before heat treatment. Therefore, in one embodiment of the present invention, it may be advantageous to use 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 1.50 or 1.15 to 1.45, from the viewpoint of ensuring the desired difference in pile length and unwinding properties. This yarn length ratio after heat treatment can be determined in the same manner as the method for determining the ratio of the length of the wrapping yarn to the length of the core yarn of the covered yarn described above, except that the measurement object is changed from the covered yarn to the covered yarn after heat treatment.

[0047] The ratio of the length of the wrapping yarn to the length of the core yarn in the covered yarn after heat treatment at 150°C for 3 minutes can be controlled by adjusting the configuration of the covered yarn (e.g., the number of coverings, the helix angle of the wrapping yarn) depending on the type, fineness, heat shrinkage rate, etc. of the core yarn and wrapping yarn used in the covered yarn. By measuring the heat shrinkage rates of the core yarn and wrapping yarn before and after heat treatment under the heat treatment conditions when producing a piled fabric in advance, it is possible to more accurately determine the target setting value (the number of coverings of the wrapping yarn) of the covered yarn production device to obtain the desired yarn length ratio after heat treatment under the specified conditions.

[0048] The diameter of the covering yarn depends greatly on the fineness of the core yarn, the fineness of the wrapping yarn, and the number of wrapping yarns. From the viewpoint of the standing property of the pile yarn, the diameter of the covering yarn is preferably 200 μm or more (e.g., 220 μm or more, 240 μm or more, or 250 μm or more). Although there are no particular upper limits for the diameter of the covering yarn, from the viewpoint of knitting and weaving properties, it is preferably 350 μm or less (e.g., 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 taken under magnification using a digital microscope.

[0049] [Winding thread] For all wrapping yarns, the breaking strength of each wrapping yarn is, for example, preferably 2 cN / dtex or more, more preferably greater than 2 cN / dtex, even more preferably 2.1 cN / dtex or more, particularly preferably 2.5 cN / dtex or more, particularly preferably 3.0 cN / dtex or more, and particularly preferably 3.3 cN / dtex or more. When the breaking strength of the wrapping yarn is above the lower limit, it is possible to prevent some of the fibers constituting the cut pile yarn from falling off when the covering yarn is unwound and / or the cut pile yarn is opened. This allows for efficient production of a coating film with excellent decorative properties on the coated surface. There is no particular upper limit for the breaking strength of the wrapping yarn, but it is usually 7.0 cN / dtex or less. The breaking strength of the wrapping yarn can be measured in accordance with JIS L 1013:2021.

[0050] In order to ensure that, when a piled fabric is formed, the cut pile yarn with the longest pile length among two or more types of cut pile yarns erected from the same base has a single fiber fineness of less than 1.3 dtex, the outermost wrapping yarn constituting the covering yarn used in the present invention usually has a single fiber fineness of less than 1.3 dtex, preferably 0.05 dtex to less than 1.3 dtex, more preferably 0.1 dtex to 1.2 dtex. The single fiber fineness of the wrapping yarns other than the outermost wrapping yarn is preferably 1.3 dtex to 15 dtex, more preferably 1.5 dtex to 12 dtex, even more preferably 2.0 dtex to 10 dtex, particularly preferably 2.5 dtex to 8 dtex, and may be, for example, 3.0 dtex or more. By forming a piled fabric from covering yarns using wrapping yarns having such single fiber finenesses, only fine fibers can be present on the outermost surface of the resulting piled fabric, and while the use of fine fibers ensures scattering prevention and a good paint finish, the presence of cut pile yarns having a thicker single fiber fineness around them prevents the pile from falling over, resulting in a thick paint film that increases the hiding power.Furthermore, shrinkage of the fiber layer including the piled portion can be suppressed, which is advantageous in terms of improving the efficiency of the painting work.

[0051] The fineness of each wrapping yarn is preferably 165 to 1000 dtex, more preferably 200 to 900 dtex, even more preferably 250 to 600 dtex, and particularly preferably 300 to 500 dtex. When the fineness of the wrapping yarn is within this range, the cut pile yarns obtained after unwinding have excellent standability, and a piled portion with a sufficient difference in pile length can be formed. The fineness of the wrapping yarn can be measured in accordance with JIS L 1013:2021.

[0052] The outermost wrapping yarn of the covering yarn is a false-twisted yarn or a composite yarn containing a false-twisted yarn. The false-twisted yarn or composite yarn containing a false-twisted yarn is preferably one that satisfies the physical properties and characteristics, such as breaking strength, crimp elongation, torque, etc., of at least the cut pile yarn having the longest pile length, described above, which constitutes the piled fabric of the present invention.

[0053] In the production of the piled fabric of the present invention, it is preferable to use a covering yarn in which the outermost wrapping yarn (false-twisted yarn or false-twisted-yarn-containing composite yarn) has torque and the wrapping yarn is wound around the core yarn in the opposite direction to the torque. Here, "wound in the opposite direction to the torque of the wrapping yarn" means that if the torque of the wrapping yarn is in the S direction, the wrapping yarn is wound in the Z direction, and if the torque of the wrapping yarn is in the Z direction, the wrapping yarn is wound in the S direction. This configuration allows the outermost wrapping yarn to be unwound as desired. On the other hand, if the wrapping yarn is wound in the same direction as its torque, it generally tends to be difficult to unwind.

[0054] The inventors also discovered that the greater the torque of the wrapping yarn wound in the opposite direction to the torque of the wrapping yarn itself, the more secure the unwinding property of the wrapping yarn can be, even if the covering number of the wrapping yarn is set to a higher number. Since an increase in the covering number results in an increase in the ratio of the length of the wrapping yarn to the length of the core yarn, the greater the torque of the wrapping yarn wound in the opposite direction to the torque of the wrapping yarn itself, the greater the ratio of the length of the wrapping yarn to the length of the core yarn can be while ensuring the unwinding property of the wrapping yarn. From this perspective, it is preferable that at least the outermost wrapping yarn, a false-twisted yarn or false-twisted-yarn-containing composite yarn, has a torque of preferably 30 t / m or more, more preferably 50 t / m or more, even more preferably 60 t / m or more, and particularly preferably 80 t / m or more. From the viewpoints of preventing the occurrence of billets (snarls) and ease of handling, the upper limit of the torque is preferably 120 t / m or less, more preferably 110 t / m or less, and even more preferably 100 t / m or less. The torque in the present invention can be measured by the method described in the Examples below.

[0055] When multiple wrapping yarns are present, examples of the type of yarn constituting the inner wrapping yarn include spun yarn, false twisted yarn, and false twisted yarn-containing composite yarn. Of these, false twisted yarn or false twisted yarn-containing composite yarn is preferred from the viewpoint of the standability of the cut pile yarn. The crimp elongation, presence or absence of torque, magnitude of torque, and relationship between torque and winding direction of the false twisted yarn or false twisted yarn-containing composite yarn serving as the inner wrapping yarn are not particularly limited. From the viewpoint of the unwinding ability of the inner wrapping yarn or a larger yarn length difference between the core yarn and the inner and outer wrapping yarns, the crimp elongation, presence or absence of torque, magnitude of torque, and relationship between torque and winding direction of the false twisted yarn or false twisted yarn-containing composite yarn serving as the inner wrapping yarn may be the same as the crimp elongation, presence or absence of torque, magnitude of torque, and relationship between torque and winding direction of at least the false twisted yarn or false twisted yarn-containing composite yarn serving as the outermost wrapping yarn, as described above.

[0056] In one embodiment of the present invention, all wrapping yarns intended to be unwound in the process of producing a piled fabric, preferably all wrapping yarns of the covering yarns forming the piled fabric, are false-twisted yarns or composite yarns containing false-twisted yarns. In this embodiment, the types and physical properties of the wrapping yarns may be the same or different. In this embodiment, the embodiment of at least the outermost wrapping yarn may be the embodiment of the outermost wrapping yarn described above, particularly the preferred embodiment. In this embodiment, when there are multiple wrapping yarns, the embodiment of the inner wrapping yarn may be the embodiment of the inner wrapping yarn described above, particularly the preferred embodiment.

[0057] For wrapping yarns other than the outermost wrapping yarn, if the false twist yarn or false twist-yarn-containing composite yarn that constitutes the wrapping yarn has torque, it is difficult to unwind the wrapping yarn if the wrapping yarn is wound in the same direction as its own torque. This is thought to be because winding in the same direction as the torque of the yarn makes it difficult to form a space at the interface between the wrapping yarn and the yarn being wound around it. Therefore, a configuration intended to prevent specific wrapping yarns other than the outermost wrapping yarn from being unwound can be achieved by winding the wrapping yarn in the same direction as its own torque. For example, the above-mentioned embodiment 1-1 can be obtained by using a double-covering yarn in which the inner wrapping yarn is wound around the core yarn in the same direction as its own torque.

[0058] For wrapping yarns other than the outermost wrapping yarn, if the false twisted yarn or false twisted yarn-containing composite yarn that constitutes the wrapping yarn has torque, the wrapping yarn can be unwound as desired if it is wound in the opposite direction to its own torque. This is thought to be due to the physical effect of winding the wrapping yarn in the opposite direction to the torque of the yarn, creating a space at the interface between the wrapping yarn and the yarn being wound. Furthermore, the greater the torque of a wrapping yarn wound in the opposite direction to its own torque, the easier it is to ensure the unwinding of the wrapping yarn, even if the covering number of the wrapping yarn is set to a higher number. Since an increase in the covering number increases the ratio of the length of the wrapping yarn to the length of the core yarn, the greater the torque of a wrapping yarn wound in the opposite direction to its own torque, the greater the ratio of the length of the wrapping yarn to the length of the core yarn can be while ensuring the unwinding of the wrapping yarn. For example, the above-mentioned embodiment 1-2 can be achieved by using a single-covered yarn in which the wrapping yarn is wound around the core yarn in the opposite direction to its own torque. Moreover, the above-mentioned second embodiment can be obtained by using a double-covering yarn in which the inner and outer wrapping yarns are wound in the opposite directions to their own torque.

[0059] In one embodiment of the present invention, the raised fabric is formed using single covered yarns.

[0060] In another embodiment of the present invention, the piled fabric is formed using double-covered yarn. Furthermore, by changing the configuration of the double-covered yarn as follows, piled fabrics of various types can be obtained. For example, by using a double-covered yarn in which the inner wrapping yarn is wound in the opposite direction to its own torque, the inner wrapping yarn as well as the outer wrapping yarn can be unwound as desired, thereby producing a piled fabric in which three types of cut pile yarns with different pile lengths are erected from the same base.

[0061] Furthermore, by using a double-covered yarn in which the inner wrapping yarn is wound in the same direction as its own torque, the outer wrapping yarn can be designed to be easily unwound as desired, while the inner wrapping yarn can be designed to be difficult to unwind as desired. This makes it possible to obtain a piled fabric in which two types of cut pile yarn with different pile lengths are erected from the same base.

[0062] Double-covered yarns, in which the inner and outer wrapping yarns are wound in opposite directions, can be handled without birring. This is particularly preferred when the design is intended to unwind both the outer and inner wrapping yarns, but it can also be applied when the design is intended to unwind only the outer wrapping yarn, but not the inner wrapping yarn.

[0063] It is also possible to use a double-covered yarn, in which the inner and outer wrapping yarns are wound in the same direction. This is particularly preferred when the design is intended to unwind only the outer wrapping yarn and not the inner wrapping yarn, but it can also be applied when the design is intended to unwind both the outer and inner wrapping yarns.

[0064] The above description of the torque and winding direction of the wrapping yarn is, in principle, a suitable relationship when the false-twisted yarn or false-twisted-yarn-containing composite yarn (abbreviated as false-twisted yarn, etc.) has not been heated before dyeing or producing a covered yarn. For example, when a dyed false-twisted yarn, etc., is used as the false-twisted yarn that constitutes the wrapping yarn of the covered yarn, the original torque of the false-twisted yarn, etc., may be thermally fixed by the heat generated during the dyeing process, resulting in a substantially non-torque false-twisted yarn, etc. When such a false-twisted yarn, etc., is used as a covered yarn, it is preferable to twist the false-twisted yarn, etc., alone (additional twist) to generate torque again. In this case, the direction in which torque is generated is opposite to the twisting direction. In other words, when twisted in the Z direction, torque is generated in the S direction. In the present invention, when the intention is to unwind the wrapped yarn, it is preferable to wind it in the opposite direction to the torque of the wrapped yarn, and therefore, when using a dyed false-twisted yarn or the like that is twisted, the wrapped yarn made of the false-twisted yarn or the like is easily unwound if it is wound in the same direction as the twist direction of the false-twisted yarn or the like. Conversely, when the wrapped yarn is not intended to be unwound, it is preferable to wind it in the opposite direction to the twist direction of the false-twisted yarn or the like. Note that this relationship is not limited to dyed false-twisted yarn or the like; for example, even with raw silk that does not originally have torque, the same effect (ease of unwinding) as above can be obtained by twisting it alone and winding it in the twisting direction.

[0065] In one embodiment of the present invention, for a wrapping yarn when a single covering yarn is used to produce a piled fabric, or for an inner wrapping yarn when a double covering yarn is used, the fineness D1 of the core yarn, the fineness D2 of the wrapping yarn, and the covering number T1 of the wrapping yarn satisfy the following relationship: 330dtex≦total fineness<1550dtex, 70≦T1<500 [Total fineness is D1 + D2] It is preferable that the following relationship be satisfied. The covering number of the wrapping yarn in this specification is a value measured with reference to "Measurement of twist number" described in C.10 of JIS L 1095:2010, more specifically, a value measured by the method described in the Examples section below. When the covering yarn satisfies the above relationship, the wrapping yarn in the case of a single-covered yarn or the inner wrapping yarn in the case of a double-covered yarn can be unwound more smoothly.

[0066] In one embodiment of the present invention, when double-covered yarns are used to produce a piled fabric, the fineness D1 of the core yarn, the fineness D2 of the inner wrapping yarn, the fineness D3 of the outer wrapping yarn, and the covering number T2 of the outer wrapping yarn satisfy the following relationship: 50dtex≦total fineness<2000dtex 70≦T2<500 [Total fineness is D1 + D2 + D3] When the covering yarn satisfies the above relationship, the outer wrapping yarn in the case of a double covering yarn can be unwound more satisfactorily.

[0067] The preferred helix angle of the wrapping yarn varies depending on the configuration of the covering yarn. The helix angle of the covering yarn can be determined using a magnified photograph of the covering yarn.

[0068] Alternatively, the diameter of the covering yarn and the distance between adjacent wrapped yarns can be used to determine the diameter. A specific method for determining the diameter (μm) is described below with reference to FIGS. 10 and 11. FIG. 10 shows an image of 11 randomly selected adjacent covering yarns, taken at 100x magnification using a Keyence Corporation (Model VHX-5000) magnifier, after wrapping the covering yarns that can be used in the present invention around hard paper, with the covering yarns slightly offset so as not to overlap and without applying a tensile force of 2 cN or more. First, a representative crease 44 is drawn on the image of each covering yarn, and the distance d1 is measured at five locations (only one location is shown in FIG. 10 for clarity), and the average value is calculated to determine the diameter (μm) of the covering yarn. Next, the average of the 11 diameters is calculated to determine the diameter (μm) of the covering yarn being measured. Next, seven straight lines 45 (dashed lines) are drawn along the wrapping yarn, and the distance 46 (corresponding to the distance between the wrapping yarns) (μm) between adjacent straight lines 45 is measured (only one is shown in FIG. 10 for ease of viewing). These distances are averaged to determine the distance between the wrapping yarns (μm) for that covering yarn. Next, the average of 11 of these distances is calculated to determine the distance between the wrapping yarns (μm) for the covering yarn being measured. Note that while FIG. 10 shows auxiliary lines (such as lines 44-46) for one covering yarn for ease of viewing, in reality, auxiliary lines are similarly drawn for each of the 11 covering yarns to determine the diameter of the covering yarn and the distance between adjacent wrapping yarns.

[0069] The arrangement of the core yarn and wrapping yarn in a covering yarn can be represented by a schematic diagram showing a parallelogram paper (wrapping yarn) being wound around a cylindrical object (core yarn) at a helix angle θ3 (radians) (see Figure 9). In Figure 11, D and E are the vertices of the parallelogram paper, F is the intersection of a line drawn from vertex E to the side of the parallelogram paper so that angle DFE is a right angle, and G is the intersection of a line drawn from vertex E to the side of the parallelogram paper so that angle DEG is a right angle. As is clear from Figure 11, θ3' corresponds to the helix angle θ3, and therefore sin θ3 can be expressed by the following formula. sinθ3 = (length of line segment EF) / (length of line segment EG) Here, the length of the line segment EG is equal to π × (diameter of the covering thread d2), so sinθ3 = (length of line segment EF) / (πd2) The helix angle θ3 can be calculated by substituting the distance between adjacent wrapping yarns obtained from FIG. 10 as the length of the line segment EF and the diameter of the covering yarn obtained from FIG. 10 as d2.

[0070] The polymer constituting the wrapping yarn is not particularly limited, and the type of polymer constituting the wrapping yarn, as well as the structure, cross-sectional shape, and single yarn fineness of the wrapping yarn, may be the same as those of the cut pile yarn constituting the piled fabric.

[0071] [Coiling yarn] The breaking strength of the core yarn is, for example, preferably 2 cN / dtex or more, more preferably greater than 2 cN / dtex, even more preferably 2.1 cN / dtex or more, particularly 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 above the lower limit, it is possible to prevent some of the fibers constituting the cut pile yarn from falling off when the covering yarn is unwound and / or the cut pile yarn is opened. This allows for the production of a piled fabric with excellent texture and appearance. 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 wrapping yarn.

[0072] The core yarn preferably has a single fiber fineness of 1.3 dtex to 15 dtex, more preferably 1.5 dtex to 12 dtex, even more preferably 2.0 dtex to 10 dtex, and particularly preferably 2.5 dtex to 8 dtex, and may be, for example, 3.0 dtex or greater. By forming a piled fabric from a covering yarn using a core yarn having such a single fiber fineness, only fine fibers can be present on the outermost surface of the resulting piled fabric. While the use of fine fibers ensures the scattering suppression and excellent paint finish effect achieved by using fine fibers, the presence of cut pile yarns with a thicker single fiber fineness around the fine fibers suppresses pile collapse of the cut pile yarns, resulting in a thicker paint film and an increased hiding power. Furthermore, shrinkage of the fiber layer, including the napped portion, can be suppressed, which is advantageous in terms of improving the efficiency of the paint work.

[0073] The fineness of the core yarn is preferably 165 to 1500 dtex, more preferably 200 to 1200 dtex, even more preferably 300 to 800 dtex, and particularly preferably 400 to 600 dtex. When the fineness of the core yarn is within this range, the cut pile yarn obtained after unwinding has excellent standability and can form a piled portion with a sufficient difference in pile length. The fineness of the core yarn can be measured in accordance with JIS L 1013:2021, as with the fineness of the wrapping yarn.

[0074] It was found that, when the fineness of the core yarn is kept constant, the unwinding property of the wound yarn can be ensured even if the covering number of the wound yarn is set higher as the fineness of the core yarn increases. In other words, the difference between the length of the core yarn and the length of the wound yarn can be increased. On the other hand, it was found that, when the fineness of the core yarn is kept constant, the unwinding property of the wound yarn can be ensured even if the covering number is set higher as the fineness of the winding yarn increases.

[0075] The type of yarn constituting the core yarn is not particularly limited, and examples thereof include spun yarn, false-twisted yarn, and false-twisted-yarn-containing composite yarn. Of these, false-twisted yarn or false-twisted-yarn-containing composite yarn is preferred from the viewpoint of the standability of the resulting cut pile yarn.

[0076] The crimp elongation of the false-twisted yarn or false-twisted yarn-containing composite yarn used as the core yarn is not particularly limited, but from the viewpoint of ensuring a sufficient difference in pile length in the piled fabric and from the viewpoint of the volume of the piled portion, it is preferable that the core yarn satisfy the physical properties and characteristics such as the crimp elongation and torque of the cut pile yarn described above as constituting the piled fabric of the present invention.

[0077] Furthermore, there are no particular limitations on whether or not the twisted yarn or twisted yarn-containing composite yarn used as the core yarn has torque, and the magnitude of the torque. However, from the viewpoint of suppressing the occurrence of rips, it is preferable that the torque be 20 t / m or less, more preferably 10 t / m or less, and even more preferably 7 t / m or less, or that the core yarn have 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 configuration, cross-sectional shape, and single yarn fineness of the core yarn, may be the same as those of the cut pile yarn constituting the pile fabric.

[0079] [Covering yarn manufacturing method] The covered yarn described above can be produced by a method known in the art using a production apparatus known in the art, such as the one shown in the schematic diagram of Figure 12. One example of such a method, in the case of a single-covered yarn, is to pass the core yarn fed from a core-yarn cheese through a hollow spindle, rotate a winding yarn bobbin mounted on the hollow spindle, and wind the winding yarn around the core yarn a predetermined number of coverings, and then wind the resulting covered yarn. An example of a production method in which multiple winding yarns are wound is the same as the example of a production method for a single-covered yarn described above, except that multiple winding yarn bobbins mounted on a hollow spindle are present and rotated to sequentially wind the winding yarn around the core yarn a predetermined number of coverings.

[0080] By inputting the fineness of the core yarn and the wrapping yarn and an arbitrary covering number into the above-mentioned formula (1), the helix angle θ of the wrapping yarn can be calculated. By inputting this into formula (2), the ratio of the length of the wrapping yarn to the length of the core yarn can be determined, making it possible to produce a covered yarn having a desired ratio of the length of the wrapping yarn to the length of the core yarn. The fine adjustment of the covering number described above is necessary when the set covering number and the actually measured covering number differ. For example, if the actually measured covering number is slightly smaller than the set covering number, the set covering number can be slightly increased to obtain the desired yarn length ratio.

[0081] (Cut pile fabric manufacturing process) In the cut pile fabric production process, the covering yarn prepared in the covering yarn preparation process is used in a manufacturing apparatus known in the art, such as a sinker pile knitting machine, a seal rib knitting machine, a double velvet loom, a tricot knitting machine, a Russell knitting machine, or a tufting machine, to produce a cut pile fabric by a method known in the art.

[0082] (Nap production process) Next, the covering yarn that constitutes the piled portion of the cut pile fabric is 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 piled portion forming step, it is possible to form a piled portion that is composed of two or more cut pile yarns with different pile lengths, for example, corresponding to the difference in yarn length between the core yarn and the wrapping yarn.

[0083] When the covering yarn is a double-covered yarn, by unwinding both the outer and inner wrapping yarns of the double-covered yarn in the piled portion forming step, a piled fabric can be obtained in which three types of cut pile yarns with different pile lengths are erected from the same base. In this embodiment, the double-covered yarn constituting the cut pile fabric preferably has both the inner and outer wrapping yarns with torque, and each wrapping yarn is wound around the core yarn in the direction opposite to its own torque. With this type of double-covered yarn, both the inner and outer wrapping yarns can be easily unwound.

[0084] When the covering yarn is a double-covered yarn, by unwinding only the outer wrapping yarn of the double-covered yarn in the pile-raising portion-forming step, a piled fabric can be obtained in which two types of cut pile yarns with different pile lengths are erected from the same base. In this embodiment, the double-covered yarn constituting the cut pile fabric preferably has an inner wrapping yarn and an outer wrapping yarn both with torque, with the inner wrapping yarn wound around the core yarn in the same direction as its own torque and the outer wrapping yarn wound in the opposite direction to its own torque. With this type of double-covered yarn configuration, the outer wrapping yarn can be easily unwound without unwinding the inner wrapping yarn. The above description is based, in principle, on the relationship when the same type of yarn is used. That is, the difference in the length of the cut pile yarn in the final piled fabric is determined by the difference in the length of the core yarn and the wrapping yarn that make up the covering yarn, as described above, and their unwinding properties, but it can also be controlled by the type of core yarn and / or wrapping yarn. For example, when a piled fabric is produced by unwinding both the outer wrapping yarn and the inner wrapping yarn of a double-covering yarn, depending on the type of core yarn and / or wrapping yarn (e.g., differences in shrinkage rate due to heating), a piled fabric with two different pile length differences may be obtained, or a piled fabric with three different pile length differences may be obtained. When using cut pile yarn that shrinks upon heat treatment, the cut pile length can be set taking this shrinkage into account. With ordinary textured yarn, this design requirement can be determined by the shrinkage rate of the yarn and the feed rate of the pile yarn on the loom.

[0085] The covering yarn can be unwound, for example, by pressing a cardboard cloth against the cut pile fabric and moving it in a predetermined direction (combing the fibers). This method can employ the techniques used in conventional splitting (spreading) in the manufacture of cut pile fabrics. By controlling the needle's penetration depth into the cut pile fabric, the desired winding of the covering yarn that constitutes the cut pile yarn can be unwound. The needle's penetration depth can be determined appropriately depending on the configuration of the cut pile fabric to be unwound. However, if the needle penetrates too deeply, the pile yarn may come out of the ground weave during the splitting operation. Therefore, in the present invention, the pile yarn up to about 4 mm from the base does not need to be unwound. There are no particular restrictions on the cardboard cloth used, and those used in conventional splitting processes can be used. Depending on the unwinding conditions, conventional splitting (spreading) can be performed simultaneously. By appropriately selecting the winding direction and number of coverings of the covering yarn that constitutes the cut pile yarn of the piled portion, the desired wrapped yarn can be easily unwound. In addition, since the covering yarn can be unwound uniformly over the entire desired area, a uniform piled portion can be formed.

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

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

[0088] The piled fabric of the present invention can be produced by forming a piled portion using a covering yarn and then unwinding it. This allows for easy production of a piled fabric that satisfies the required configuration, regardless of the settings of the production equipment, with a long pile length for the cut pile yarn. Furthermore, because the difference in pile length between the cut pile yarns can be easily controlled, a piled fabric with a specific pile length difference can be efficiently produced using a standard production equipment. Therefore, the piled fabric of the present invention is suitable as a piled fabric for a paint tool, as it suppresses paint splashing during painting work, is less likely to cause shrinkage of the fiber layer during painting work, and can provide a paint finish with excellent hiding power and aesthetic appeal with good workability. Therefore, the present invention also covers a roller-type paint tool including the piled fabric for a paint tool of the present invention. The roller-type paint tool of the present invention is not particularly limited in its configuration, as long as it can wrap and secure the piled fabric of the present invention around the outer periphery of a roller core material, and conventionally known components of a roller-type paint tool can be used as appropriate. [Example]

[0089] The present invention will be described in detail below with reference to examples, but the scope of the present invention is not limited to these examples. The methods for measuring the physical properties of the core yarn, wrapping yarn, and covering yarn are described below. However, the physical properties and measurements (or physical property values and measured values) described in this specification, including the examples, are based on values determined by the following methods.

[0090] <Crimp elongation rate> The sample was wound into a 5000 denier (d) skein using a skein winder. The upper part of the wound sample was fixed, and a 10 g load was applied to the wound sample so that a load of 0.001 g / d was applied. With this load applied, the sample was immersed in hot water at 90°C for 30 minutes. The sample was removed from the hot water and dried overnight under no load at room temperature (20°C ± 2°C) and a relative humidity of 65 ± 4%. Under the same conditions, a 10 g load was again applied to the sample. After leaving the sample for 5 minutes, the yarn length (L0 [mm]) was measured with the load still applied. Next, under the same conditions, a 1.0 kg load was applied to the sample so that a load of 0.0001 g / d was applied. After leaving the sample for 30 seconds, the yarn length (L1 [mm]) was measured with the load still applied. The crimp elongation K1 was calculated using the following formula: The crimp elongation was determined by measuring 5 times, and the average value was taken as the crimp elongation of the sample. K1 [%] = {(L1-L0) / L1} × 100

[0091] <Single fiber fineness / fineness> The single fiber fineness and fineness of each yarn were measured in accordance with JIS L 1013: 2021. Five measurements were made, and the average value was taken as the fineness of the yarn.

[0092] <150℃ dry heat shrinkage rate: Dsr150> A sample was wound 10 times using a 1 m skein winder. The upper part of the wound sample was fixed, and a load of 0.001 g / d was applied to the wound sample. The length of the sample was measured with the load applied, and this was designated L0. Next, the sample was immersed in a 150°C thermostatic bath for 3 minutes without load, and the length was measured again under a load of 0.001 g / d, and this was designated L1. The thermal shrinkage Dsr150 was calculated using the following formula. Dsr(%)=(L0-L1) / L0×100

[0093] <torque> A 1-g weight was hung from the center of a 1-m-long sample to generate torque, and the number of twists per 50 cm was measured. This number of twists was converted into the number of twists per meter, and this value was taken as the torque of the sample. When observing the rotation of the weight from above, the direction of torque was defined as the Z direction when it was clockwise and the S direction when it was counterclockwise. For example, if the torque direction was the Z direction and the number of twists per meter was 10 t / m, the torque would be expressed as Z10 t / m.

[0094] <Number of coverings of winding thread> Measurement was carried out with reference to "Measurement of twist number" described in C.10 of JIS L 1095:2010. The gripping distance of the twist detector was set to 250 mm ± 0.5 mm (i.e., this distance was the sample length), and the covered yarn (sample) to be measured was set in place. If the core yarn of the covered yarn was untwisted, the core yarn would be twisted as the untwisting progressed, causing the entire covered yarn to begin shrinking. One of the non-rotating gripping parts was designed to be movable in the longitudinal direction of the sample so that measurements could be made even when the yarn shrunk. Furthermore, if the covered yarn was a double-covered yarn, after measuring the number of coverings of the outer wrapped yarn, the rotation counter was rotated in the opposite direction to return it to its original position. The number of coverings of the inner wrapped yarn was then measured in the same way as the number of coverings of the outer wrapped yarn. Five measurements were made, and the average was calculated. This was then converted to the number of rotations per meter to determine the number of coverings of the wrapped yarn. For example, if the wrapping direction is Z and the number of rotations per meter is 10 t / m, the number of coverings is expressed as Z10t / m.

[0095] <Length of covering yarn, ratio and difference of length of wrapping yarn to length of core yarn> A 300 mm long covering yarn to be measured was placed on a mount, and both ends of the sample were fixed to the mount with cellophane tape so that the sample length was 200 mm and a tensile force of 2 cN or less was not applied. Next, the sample was cut using a cutter at the boundary between one of the cellophane tapes and the sample, leaving one end of the sample as the free end. The free end was pinched and the wrapped yarns were carefully unwound (starting with the outermost wrapped yarn if multiple wrapped yarns were present) so that a tensile force of 2 cN or less was not applied. The yarn lengths of the wrapped yarn and core yarn were measured using a ruler with a minimum division of 1 mm while applying a tensile force of 2 cN. Five measurements were taken, and the average was used as the yarn length for each yarn. The ratio of the wrapped yarn length to the core yarn length was then calculated. The test was conducted at room temperature of 20°C ± 2°C and a relative humidity of 65 ± 4%.

[0096] <Cut pile length> A 20cm section was cut out along the warp from the back of the piled fabric to include approximately three rows of pile yarns in the ground weave. The lengths of the long and short cut pile yarns within this section were measured by pressing a ruler against the row of cut pile yarns while the row was laid on its side to avoid excessive stretching of the cut pile yarns. Using a ruler with a minimum scale of 1.0mm, the length from the base of each cut pile yarn to its tip was visually read to 1 / 10 of the scale. The lengths of the longest and shortest cut pile yarns erected from the same base were measured, and the ratio of the long cut pile yarn to the short cut pile yarn was calculated for each pair of cut pile yarns erected from the same base. The average of the ratios for all pairs within the measurement range was taken as the pile length ratio. In addition, the lengths of the longest and second longest cut pile yarns erected from the same base were measured, and the difference between these lengths was calculated for each pair of cut pile yarns erected from the same base. The average value of the differences between all pairs within the measurement range was taken as the difference in pile length.

[0097] 1. Preparation of piled fabric Table 1 shows the types of yarns used to prepare the piled fabrics of the Examples and Comparative Examples and their physical properties.

[0098] [Table 1]

[0099] (1) Example 1 (i) Preparation of covering thread 1 The core yarn is a polyester 165 dtex 48 filament two-stage heater non-torque false-twisted yarn (Yarn A in Table 1, crimp elongation: 10.6%, Dsr150: 32.4%), and the inner wrapping yarn is a polyester air-blended yarn 330 dtex 132 filament (Yarn B in Table 1, crimp elongation: 23.6%, Dsr150: 34.8%) consisting of a two-stage heater false-twisted yarn with torque in the S direction, with a covering number of 465 t / s in the Z direction. The yarn was wound at a length of 166 dtex and 144 filaments, and two polyester two-stage heater false-twisted yarns with torque in the Z direction (Yarn C in Table 1, single fiber fineness: 1.1 dtex, crimp elongation: 18.8%, Dsr150: 28.6%) were aligned and air-blended to form 330 dtex and 288 filaments, which were then double-covered in the S direction at a covering number of 405 t / m, to obtain double-covered yarn 1 shown in Table 2.

[0100] (ii) Manufacture of moquette fabric A moquette was produced using double covering yarn 1 as follows. Double covering yarn 1 was wound onto a warp beam. The moquette used a polyester spun yarn 20 / 2 as the ground warp yarn and a polyester spun yarn 20 / 1 as the weft yarn. The base fabric had a warp density of 43 threads / inch and a weft density of 40 threads / inch. The pile length (preset length) on the loom was set so that the cut pile length of the highest cut pile yarn in the final finished product would be 25 mm. A cut pile fabric was woven using covering yarn 1. The resulting fabric was split in the usual way to unwind the double covering yarn. The cut pile yarn on the surface was then straightened using a shearing machine, and the back of the fabric was backed with an acrylic resin. A piled fabric was then obtained by hot air drying at 150°C for 3 minutes. The pile length ratio and pile length difference of the resulting piled fabric are shown in Table 3.

[0101] (2) Example 2 (i) Preparation of covering thread 2 Covered yarn 2 was produced in the same manner as covered yarn 1, except that the number of covers was changed as shown in Table 2.

[0102] (ii) Manufacture of moquette fabric A piled fabric was produced in the same manner as in Example 1, except that covering yarn 2 was used and the cut pile length of the tallest cut pile yarn in the final finished product was set to 17 mm. The pile length ratio and pile length difference of the resulting piled fabric are shown in Table 3.

[0103] (3) Example 3 (i) Preparation of covering thread 3 Covered yarn 3 was produced in the same manner as covered yarn 1, except that the number of covers was changed as shown in Table 2.

[0104] (ii) Manufacture of moquette fabric A piled fabric was produced in the same manner as in Example 1, except that covering yarn 3 was used. Table 3 shows the pile length ratio and pile length difference of the obtained piled fabric.

[0105] (4) Comparative Example 1 (i) Preparation of covering thread 4 Covered yarn 4 was produced in the same manner as covered yarn 1, except that the number of covers was changed as shown in Table 2.

[0106] (ii) Manufacture of moquette fabric A piled fabric was produced in the same manner as in Example 1, except that covering yarn 4 was used. Table 3 shows the pile length ratio and pile length difference of the obtained piled fabric.

[0107] (5) Comparative Example 2 (i) Preparation of covering thread 5 Covered yarn 5 was produced in the same manner as covered yarn 1, except that the number of covers was changed as shown in Table 2.

[0108] (ii) Manufacture of moquette fabric A piled fabric was produced in the same manner as in Example 1, except that covering yarn 5 was used. Table 3 shows the pile length ratio and pile length difference of the obtained piled fabric.

[0109] (6) Comparative Example 3 (i) Preparation of plied yarn The core yarn of 165 dtex and 48 filaments (Yarn A in Table 1) and the inner wrapping yarn of 330 dtex and 132 filaments (Yarn B in Table 1) used in Example 1 were aligned and twisted (60 t / m) with the outer wrapping yarn of 330 dtex and 288 filaments air-mixed yarn to obtain a doubled-twisted yarn.

[0110] (ii) Manufacture of moquette fabric A piled fabric was produced in the same manner as in Example 1, except that the plied yarn obtained above was used instead of covering yarn 1. The pile length ratio and pile length difference of the obtained piled fabric are shown in Table 3.

[0111] (7) Comparative Example 4 One 165 dtex, 48 filament yarn (Yarn A in Table 1) used as the core yarn in Example 1 and two 330 dtex, 132 filament air-mixed yarns (Yarn B in Table 1) used as the inner wrapping yarn were aligned and twisted in the Z direction at 60 t / m to prepare a yarn. This 165 dtex, 48 filament yarn and two 330 dtex, 288 filament air-mixed yarns used as the outer wrapping yarn in Example 1 were twisted in the S direction at 60 t / m to prepare a yarn. These were then made into separate warp beams and woven at the weave density of Example 1 to form a striped pattern in the warp direction, with each alternate filament. The resulting fabric was finished in the same way as in Example 1, and a piled fabric was obtained according to the same specifications as in Example 1. The pile length ratio and pile length difference of the resulting piled fabric are shown in Table 3.

[0112] [Table 2]

[0113] [Table 3]

[0114] Each cut pile yarn constituting the pile fabrics prepared in Examples 1 to 3 and Comparative Examples 1 to 4 has substantially the same physical properties (fineness, crimp elongation, torque) as the core yarn or wrapping yarn of the covering yarn from which it is derived.

[0115] 3. Evaluation of properties as a raised fabric for painting tools Each of the piled fabrics prepared in Examples 1 to 3 and Comparative Examples 1 to 4 was cut to a predetermined size to prepare a small paint roller with an outer diameter of 17 mm and a length of 6 inches. Each of the prepared paint rollers was evaluated according to the following methods. The results are shown in Table 4.

[0116] <Finished surface finish> Paint ("Eau de Coat G Eco" by Nippon Paint Co., Ltd.) was poured into a designated container, and the prepared paint roller was immersed in the paint solution to soak the fiber layer. The excess paint was lightly removed using a net attached to the container so that the paint did not drip, and then the paint was applied to plywood. Similarly to the method described above, evaluation samples were prepared using a short-pile microfiber roller (Micro Eight by Otsuka Brush Manufacturing Co., Ltd.: "Fine Fiber" in Figure 13, left), a short-pile regular-type processed yarn roller (WAKABA by Otsuka Brush Manufacturing Co., Ltd.: "Moquette Regular" in Figure 13, center), and a short-pile high-pile roller (Deluxe Woo Roller B by Otsuka Brush Manufacturing Co., Ltd.: "High-pile" in Figure 13, right). Visual evaluation was performed based on this sample, and the results were evaluated as follows: Evaluation criteria: 1: Finished surface equivalent to the "fine fiber" judgment sample 2: Finished surface equivalent to the "Moquette Regular" evaluation sample 3: Finished surface equivalent to the "high pile type" judgment sample

[0117] <Paint scattering> Paint (Nippon Paint Co., Ltd. "Odecoat G Eco") was placed in a designated dedicated container, and the prepared paint roller was immersed in the paint solution to allow the paint to soak into the fiber layer. Next, excess paint was lightly wiped off using a net attached to the container so that the paint would not drip. Finally, a pre-set area on a piece of coated paper fixed 1 m above the floor on a vertical wall was wiped with a cloth to a depth of 1.0 m. 2 During the painting work, black construction paper was laid on the floor to evaluate the scattering of paint particles. The paint scattering was evaluated based on the scattering state shown in Figure 14 as follows. Evaluation criteria: A: The paint particle scattering condition is equivalent to "Excellent ◎" or "Good ○", or even less B: Paint particle scattering condition is equivalent to "Good △~○" C: The paint particle scattering condition is equivalent to "lower limit of tolerance △" or more.

[0118] <Roller diameter> The diameter of the prepared paint roller was measured and used as the roller diameter before the test. Paint ("Eau de Coat G Eco" by Nippon Paint Co., Ltd.) was placed in a designated dedicated container, and the prepared paint roller was immersed in the paint solution to allow the paint to soak into the fiber layer. The excess paint was then lightly wiped off using a net attached to the container so that the paint did not drip. This was then rolled back and forth 100 times on plywood (equivalent to a roller running length of approximately 200 m), after which the paint roller was left to air dry for one week, and the diameter was measured again to use as the roller diameter after the test. The roller diameter shrinkage was evaluated based on the change in diameter before and after the test according to the following criteria. Evaluation criteria: No shrinkage: The difference in roller diameter is less than 5% of the roller diameter before the test Shrinkage: The difference in roller diameter is 5% or more compared to the roller diameter before the test

[0119] <Film thickness> The film thickness was measured using a mechanical measuring device (Elcometer 3230 rotary wet film thickness meter manufactured by Elcometer) in reference to JIS K5600-1-7:2014, which specifies the method for measuring the wet film thickness of paint applied to a substrate as a general rule for general test methods for paints. 2 For products aimed at 17mm, 0.4m 2 was measured on the painted samples.

[0120] [Table 4]

[0121] The piled fabrics of Examples 1 to 3 were cut pile fabrics with three different cut pile yarn heights, with the difference in pile length between the longest and second-longest cut pile yarns made of fine fibers ranging from 2.0 to 6.0 mm. Paint rollers using these piled fabrics were able to reduce paint splatter during painting due to the fine fibers on the outermost surface, resulting in a highly aesthetically pleasing paint finish. Furthermore, the cut pile yarns derived from the core yarn and inner wrapping yarns provided a fabric with sufficient settling resistance, resulting in a thicker paint film and improved hiding power. The roller diameter also demonstrated a shrinkage-suppressing effect. Furthermore, in the examples, a longer pile length was achieved after unwinding the covering yarn than the machine-set pile length. In theory, if the ratio of the average length of the longest cut pile yarn after unwinding to the machine-set pile length is increased, a piled fabric with a longer pile length can be obtained by setting a shorter binding yarn length (pile length) during production of the cut pile fabric. This allows for more stable production, which is advantageous in terms of work efficiency and cost.

[0122] In contrast, in Comparative Example 1, fine fiber was used for the longest cut pile yarn, but the difference in length between the longest and second longest cut pile yarns exceeded 6.0 mm, failing to resolve the problems associated with fine fiber (concealment and roller diameter shrinkage). In Comparative Example 2, a rigid fiber of conventional fineness was used for the longest cut pile yarn, resulting in paint splatter and a finished surface inferior to that of the piled fabric of the present invention. In Comparative Example 3, the outer wrapping yarn and inner wrapping yarn used in Example 1 were woven in parallel, with the difference in length between the two cut pile yarns being approximately 1 mm, thereby failing to fully utilize the advantages of using fine fiber. In Comparative Example 4, the outer wrapping yarn and inner wrapping yarn used in Example 1 were warped separately and woven into a striped pattern. The evaluation results for the aesthetic appearance of the finished back surface, paint splatter, roller diameter shrinkage, and concealment were all unsatisfactory. [Explanation of symbols]

[0123] 1: Raised fabric 10: Pierrection part 11: Cut pile yarn with long pile length 11-1: Cut pile yarn with the longest pile length 11-2: Cut pile yarn with the second longest pile length 12: Short pile cut yarn 13: Covering thread 14: Base 15: Thread 20: Ground Organization Department 21: Weft 22: Warp thread 31: Core thread 32: Inner wrapping thread 33: Outer wrapping thread 41: Single covering thread 42: Core yarn 43: Winding thread A: End of the wrapping yarn wound around the core yarn B: End of the wrapping yarn wound around the core yarn A': End of the wrapping yarn before being wound around the core yarn B': End of the wrapping yarn before being wound around the core yarn C: The other vertex of a right triangle with line segment A'B' as the hypotenuse θ1: Helix angle of the winding thread 44: Typical twill line 45: Straight line drawn along the wrapping thread 46: Distance between two adjacent lines 45 d1: Typical twill line distance (diameter of covering thread) φ: the angle between the representative ridge line 44 and the straight line 45 θ2: Helix angle of the winding thread D: Vertex of parallelogram paper E: Vertex of parallelogram paper F: When a straight line is drawn from vertex E to the side of the parallelogram paper so that angle DFE is a right angle, the intersection point of that line and that side G: When a straight line is drawn from vertex E to the edge of the parallelogram paper so that angle DEG is a right angle, the intersection point of that line and that edge θ3: Helix angle of the winding thread θ3': Angle equivalent to the helix angle θ3 of the winding thread DE: The distance between D and E EF: The distance between E and F 47: Double covering thread 48: Core yarn 49: Inner wrapping thread 50: Outer wrapping thread 51: Covering yarn manufacturing device 52: Core cheese 53: Hollow spindle for inner winding yarn 54: Hollow spindle belt for inner winding yarn 55: Inner winding bobbin 56: Balloon guide for inner wrapping thread 57: Hollow spindle for outer winding yarn 58: Hollow spindle belt for outer wrapping yarn 59: Bobbin for outer winding thread 60: Balloon guide for outer wrapping thread 61: Covering thread package 62: Roller 63: Guide

Claims

1. A piled fabric for a coating tool, comprising a base weave portion and a piled portion made of a plurality of cut pile yarns restrained and erected by the base weave portion, The piled portion is composed of two or more types of cut pile yarns having different pile lengths, which are derived from one covering yarn that has been at least partially unwound and which are erected from the same base, and of which the cut pile yarn having the longest pile length is a false-twisted yarn or a composite yarn comprising a false-twisted yarn having a single fiber fineness of less than 1.3 dtex, and the difference between the pile lengths of the longest and second-longest cut pile yarns among the two or more types of cut pile yarns erected from the same base is 2.0 to 6.0 mm, and the ratio of the pile lengths of the longest and shortest cut pile yarns among the two or more types of cut pile yarns erected from the same base is 1.10 to 1.

50.

2. 2. The piled fabric for paint tools according to claim 1, wherein the crimp elongation of the cut pile yarn having the longest pile length is 10% or more.

3. 2. The raised fabric for paint tools according to claim 1, wherein all of the cut pile yarns constituting the raised portion are false-twisted yarns or composite yarns containing false-twisted yarns.

4. 2. The piled fabric for paint tools according to claim 1, wherein the base weave portion comprises an unreeled covering yarn comprising a core yarn and one or more wrapping yarns wound around the core yarn, and in the piled portion, two types of cut pile yarns having different pile lengths are erected from the same base derived from one covering yarn.

5. 2. The piled fabric for paint tools according to claim 1, wherein the base weave portion includes an unreeled covering yarn comprising a core yarn and two or more wrapping yarns wound around the core yarn, and the piled portion has three types of cut pile yarns with different pile lengths standing up from the same base derived from one covering yarn.

6. 6. The pile fabric for paint tools according to claim 5, wherein the unreeled covering yarn is a double-covering yarn, and the three types of cut pile yarns constituting the piled portion are an outer wrapping yarn, an inner wrapping yarn and a core yarn of the unreeled double-covering yarn.

7. 7. The raised fabric for painters according to claim 6, wherein the inner wrapping yarn and the outer wrapping yarn of the unreeled double covering yarn are wound in opposite directions.

8. 8. The piled fabric for painters according to claim 7, wherein, of the three types of cut pile yarns erected from the same base, the cut pile yarn having the longest pile length is the outer wrapping yarn of the unwound double covering yarn, and the cut pile yarn having the shortest pile length is the core yarn of the unwound double covering yarn.

9. A method for producing the raised fabric for paint tools according to claim 1, comprising: providing a covering yarn comprising a core yarn and one or more wrapping yarns wound therearound; a step of implanting the covering yarn into a base fabric to produce a cut pile fabric including a raised portion formed from the covering yarn; and a step of unwinding the covering yarn that constitutes the pile portion of the cut pile fabric to produce a pile portion comprising two or more types of cut pile yarns having different pile lengths; Including, The method, wherein the wound yarn unwound in the step of unwinding the covering yarn is a false-twisted yarn or a composite yarn comprising a false-twisted yarn.

10. 10. The method of claim 9, wherein the covered yarn is a single covered yarn or a double covered yarn.

11. 10. The method of claim 9, wherein the covering yarn is a double-covering yarn, the inner and outer wrapping yarns both having a torque, and each wrapping yarn is wound around the core yarn in a direction opposite to its own torque.

12. Regarding the wrapping yarn when the covering yarn is a single covering yarn, or the inner wrapping yarn when the covering yarn is a double covering yarn, the fineness D of the core yarn １ , fineness of winding yarn D ２ , and the number of coverings of the winding yarn T １ is related to the following: 330 dtex≦total fineness<1550 dtex, 70≦T １ <500 [Total fineness is D １ +D ２ is] The method of claim 9 , wherein

13. When the covering yarn is a double covering yarn, the outer wrapping yarn is the core yarn fineness D. １ , the fineness of the inner winding yarn D ２ , outer winding yarn fineness D ３ , and the covering number T of the outer winding yarn ２ is related to the following: 50 dtex ≦ total fineness < 2000 dtex 70 ≦ T ２ <500 [Total fineness is D １ +D ２ +D ３ is] The method of claim 9 , wherein

14. A roller-type paint sprayer comprising the raised fabric for paint sprayers according to claim 1.

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