Resin-attached fiber substrate and method for suppressing detachment

Abstract

The problem to be solved by the invention is to provide a resin-coated fiber substrate and a method for suppressing shedding, which suppress the shedding of fiber fragments (part of synthetic fibers) from the fiber substrate and have excellent texture. The resin-coated fiber substrate of the present invention includes a fiber substrate having a spun yarn formed by including synthetic fibers, and dot-shaped resin portions provided on at least one surface of the fiber substrate. The average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, the average diameter D of the resin portion is in the range of 0.05 to 5.00 mm, the average number P of the resin portions per inch is in the range of 5.0 to 50.0 pieces / 25.4 mm, and the average diameter D and the average number P of the resin portions are provided on the fiber substrate so as to satisfy the following formula (1). 8.6 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 61.2 ··· (1)

Description

Technical Field

[0001] One aspect of the present invention relates to a resin-attached fiber substrate and a method for suppressing shedding.

Background Art

[0002] In recent years, there has been an increasing interest in environmental pollution caused by microplastics. Among them, when washing a fiber product having a spun yarn formed including synthetic fibers, it is required to suppress the shedding of fiber fragments (microfibers), which are a type of microplastics, from the fiber product. For example, Patent Document 1 below describes that by providing dot-shaped resin portions on at least one surface of a fiber substrate, the generation of fuzz can be suppressed when the fiber substrate is washed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, fuzz is only generated on the surface of the fiber substrate afterwards. In a method for suppressing the generation of such fuzz, when the fiber substrate is composed of a spun yarn formed including synthetic fibers, it is impossible to suppress the shedding of a part of the synthetic fibers (that is, fiber fragments) from the fiber substrate. Therefore, it is conceivable to suppress the shedding of fiber fragments by coating the entire surface of the fiber substrate with resin, but in this case, it is conceivable that the texture of the fiber product deteriorates.

[0005] Therefore, an object of one aspect of the present invention is to provide a resin-attached fiber substrate and a method for suppressing shedding that suppress the shedding of fiber fragments from the fiber substrate and have excellent texture.

Means for Solving the Problem

[0006] [1] The resin - attached fiber base material according to one aspect of the present invention includes a fiber base material having a spun yarn formed by including synthetic fibers, and dot - shaped resin portions provided on at least one surface of the fiber base material. The average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, the average diameter D of the resin portion is in the range of 0.05 to 5.00 mm, the average number P of the resin portions per inch is in the range of 5.0 to 50.0 pieces / 25.4 mm, and the average diameter D and the average number P of the resin portions are provided on the fiber base material so as to satisfy the following formula (1). 8.6 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 61.2 ···(1)

[0007] In this configuration, in the resin - attached fiber base material in which the average diameter D of the resin portion is in the range of 0.05 to 5.00 mm, the average number P of the resin portions per inch is in the range of 5.0 to 50.0 pieces / 25.4 mm, and the average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, the resin portion is provided so that the average diameter D and the average number P satisfy the above formula (1). Thereby, the falling off of fiber fragments from the fiber base material is suppressed, and a resin - attached fiber base material excellent in texture can be obtained.

[0008] [2] The resin - attached fiber base material according to [1], wherein the average diameter D and the average number P of the resin portion may satisfy the following formula (2). 15.7 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 38.2 ···(2) Thereby, the falling off of fiber fragments from the fiber base material is further suppressed, and a resin - attached fiber base material more excellent in texture can be obtained.

[0009] [3] The anti-drop method according to one aspect of the present invention is an anti-drop method for suppressing the dropping of a part of synthetic fibers from a fiber base material having a spun yarn formed by including synthetic fibers, and at least one surface of the fiber base material having a spun yarn with an average twist number T in the range of 0.10 to 3.00 turns / mm is provided with dot-shaped resin parts having an average diameter D in the range of 0.05 to 5.00 mm and an average number P per inch in the range of 5.0 to 50.0 pieces / 25.4 mm. The resin part forming step is to form the average diameter D and the average number P of the resin parts so as to satisfy the following formula (3). 8.6 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 61.2 ···(3)

[0010] In this method, in a resin-coated fiber base material where the average diameter D of the resin part is in the range of 0.05 to 5.00 mm, the average number P of the resin parts per inch is in the range of 5.0 to 50.0 pieces / 25.4 mm, and the average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, it has a resin part forming step in which the resin part is provided so that the average diameter D and the average number P satisfy the above formula (1). Thereby, the dropping of fiber fragments from the fiber base material is suppressed, and a resin-coated fiber base material excellent in texture can be obtained.

[0011] [4] The anti-drop method according to [3], wherein the resin part forming step may form the average diameter D and the average number P of the resin parts so as to satisfy the following formula (4). 15.7 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 38.2 ···(4)

Effect of the Invention

[0012] According to one aspect of the present invention, it is possible to suppress the dropping of fiber fragments from the fiber base material and provide a resin-coated fiber base material with excellent texture.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of one aspect of the present invention will be described, but one aspect of the present invention is not limited to these embodiments at all.

[0014] In this specification, a numerical range indicated by using "~" indicates a range including the numerical values described before and after "~" as the minimum value and the maximum value, respectively. In the numerical ranges described step by step in this specification, the upper limit value or the lower limit value of a numerical range at a certain step can be arbitrarily combined with the upper limit value or the lower limit value of a numerical range at another step. In the numerical ranges described in this specification, the upper limit value or the lower limit value of the numerical range may be replaced with the values shown in the examples. "A or B" means that either one of A and B may be included, or both may be included. The materials exemplified in this specification can be used alone or in combination of two or more kinds unless otherwise specified. The term "step" includes not only an independent step but also the step even if it cannot be clearly distinguished from other steps as long as the intended action of the step is achieved.

[0015] The resin-attached fiber base material according to this embodiment includes a fiber base material having a spun yarn formed by including synthetic fibers, and dot-shaped resin portions provided on at least one surface of the fiber base material. In the resin-attached fiber base material according to this embodiment, the average diameter D of the resin portions is in the range of 0.05 to 5.00 mm, the average number P of the resin portions per inch is in the range of 5.0 to 50.0 pieces / 25.4 mm, the average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, and the average diameter D, the average number P, and the average twist number T satisfy the following formula (1). 8.6 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 61.2 ···(1) Hereinafter, the numerical value of "[D / {25.4 / (P - 1)}]×P / T" will be referred to as "parameter X" in some cases.

[0016] The resin - attached fiber base material according to the present embodiment can increase the improvement rate (hereinafter referred to as "drop - off improvement rate") regarding the drop - off of fiber fragments, which will be described in detail later. According to the resin - attached fiber base material of the present embodiment, a drop - off improvement rate of 10% or more can be achieved. According to the resin - attached fiber base material of the present embodiment, a good texture can be obtained. For example, according to the resin - attached fiber base material of the present embodiment, in the evaluation method described in the examples below, an evaluation of "B" or higher can be obtained. Also, according to the resin - attached fiber base material of the present embodiment, a good appearance quality can be obtained. For example, according to the resin - attached fiber base material of the present embodiment, in the evaluation method described in the examples below, an evaluation of "B" or higher can be obtained.

[0017] According to one aspect of the resin - attached fiber base material of the present embodiment, the average diameter D, the average number P, and the average twist number T can satisfy the following formula (2). 15.7≦[D / {25.4 / (P - 1)}]×P / T≦38.2···(2) According to one aspect of the resin - attached fiber base material of the present embodiment, a drop - off improvement rate of 30% or more can be achieved. According to the resin - attached fiber base material of the present embodiment, a good texture can be obtained. For example, according to the resin - attached fiber base material of the present embodiment, in the evaluation method described in the examples below, an evaluation of "A" or higher can be obtained.

[0018] According to one aspect of the resin - attached fiber base material of the present embodiment, the average diameter D, the average number P, and the average twist number T can satisfy the following formula (2 - 1). 31.3≦[D / {25.4 / (P - 1)}]×P / T≦36.4···(2 - 1) According to one aspect of the resin - attached fiber base material of the present embodiment, a drop - off improvement rate of 35% or more can be achieved. According to the resin - attached fiber base material of the present embodiment, a good texture can be obtained. For example, according to the resin - attached fiber base material of the present embodiment, in the evaluation method described in the examples below, an evaluation of "A" or higher can be obtained.

[0019] From the perspective of easily obtaining excellent processability, the fibrous substrate may be a fibrous fabric. The weave of the fibrous fabric is not particularly limited. Examples of the weave of the fibrous fabric include plain weave, twill weave, satin weave, and rib weave. The weave of the fibrous fabric may be plain weave or twill weave from the perspective of being easily processed to provide a resin portion. The weave of the fibrous fabric may be a multi-layer weave such as double weave (biaxial weave) or triple weave. The weave of the fibrous fabric may be a modified weave such as twill weave or rib weave. The weave of the fibrous fabric may be a special weave such as imitation yarn weave or sand grain weave. The weave of the fibrous fabric may be other weaves. The fibrous substrate may be a fibrous knitted fabric.

[0020] The fibrous substrate has spun yarns formed including synthetic fibers. When the fibrous substrate is a fibrous fabric, the warp and weft are not limited to being composed of one type of fiber. The warp and weft may be spun yarns formed from different types of synthetic fiber staple fibers (spun). Examples of synthetic fibers include nylon fiber, polyester fiber, acrylic fiber, urethane fiber, polypropylene fiber, polyethylene fiber, and polyvinyl chloride fiber. The synthetic fiber may be a regenerated fiber such as rayon or cupra, or a semi-synthetic fiber such as acetate or triacetate. In addition to synthetic fibers, the fibrous substrate may contain inorganic fibers and natural organic fibers. Examples of inorganic fibers include glass fiber, carbon fiber, metal fiber, and ceramic fiber. Examples of natural organic fibers include cotton, hemp, silk, and wool.

[0021] The spun yarns formed including synthetic fibers may be formed from one yarn or multiple yarns. When the spun yarns are formed from multiple yarns, the number thereof can be 3 or less, and preferably 2 or less in consideration of the balance between the texture and strength of the yarns.

[0022] The average twist number T of the spun yarns constituting the fiber substrate can be 0.10 to 3.00 turns / mm. Considering the viewpoint of suppressing the shedding of fiber fragments from the fiber substrate, the average twist number T of the spun yarns can be 0.15 turns / mm or more, 0.20 turns / mm or more, 0.25 turns / mm or more, 0.30 turns / mm or more, or 0.35 turns / mm or more, or 0.40 turns / mm or more. It is preferably 0.25 turns / mm or more, and more preferably 0.35 turns / mm or more.

[0023] Also, considering the viewpoint of softening the texture of the spun yarns, it can be 2.00 turns / mm or less, 1.50 turns / mm or less, 1.20 turns / mm or less, 1.00 turns / mm or less, or 0.94 turns / mm or less. It is preferably 1.20 turns / mm or less, and more preferably 0.94 turns / mm or less. The average twist number T of the spun yarns constituting the fiber substrate can be 0.15 to 2.00 turns / mm, 0.20 to 1.50 turns / mm, 0.25 to 1.20 turns / mm, 0.30 to 1.00 turns / mm, or 0.35 to 0.94 turns / mm.

[0024] The average twist number T of the spun yarns can be measured by the following method. Extract 20 spun yarns from the warp of the resin-coated fiber substrate, and measure the twist numbers of the obtained 20 spun yarns in accordance with "JIS L 1095:2010 Measurement of Twist Number". The average value of 10 measurement values excluding the 5 measurement values counted from the maximum and the 5 measurement values counted from the minimum is taken as the average twist number of the warp spun yarns. Extract 20 spun yarns from the weft of the resin-coated fiber substrate, and obtain the average twist number of the weft spun yarns in the same manner as for the warp. The average value of the average twist number of the warp spun yarns and the average twist number of the weft spun yarns is taken as the average twist number T of the spun yarns. In the case where the warp or weft does not contain spun yarns and the average twist number of the warp spun yarns or the average twist number of the weft spun yarns cannot be obtained, the average twist number of the weft spun yarns or the average twist number of the warp spun yarns is taken as the average twist number T of the spun yarns.

[0025] The resin part is attached to the fiber base material. The resin part is provided in a dot shape on at least one surface of the fiber base material. The resin part may be attached only to one surface of the fiber base material or may be attached to both surfaces of the fiber base material. "Dot shape" usually means that a plurality of circular (substantially circular (including a perfect circle) or substantially elliptical) points are regularly arranged, but the shape or arrangement pattern of each point is not particularly limited. For example, the shape of each point may be a square shape, a hexagonal shape, a star shape, etc. Also, each point may be arranged irregularly.

[0026] As long as the resin forming the resin part can be fixed to the surface of the fiber base material having the spun yarn, it is possible to suppress the shedding of fiber fragments from the fiber base material. Therefore, as the resin forming the resin part, a known binder resin for printing on fiber base materials can be used. Examples of such resins for forming the resin part include a thermoplastic resin and a curable resin that cures with heat and ultraviolet rays. More specifically, examples of the resin for forming the resin part include polyurethane, acrylic, polyamide, polyester, polyolefin, vinyl acetate, epoxy, silicone resin, and polyvinyl alcohol-based resin, etc. From the viewpoint of good water resistance and availability at low cost, acrylic resin is particularly preferable. Examples of the acrylic resin include a homopolymer containing any one of monomers such as acrylic acid, methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, 2-butylhexyl acrylate, 2-dimethylaminoethyl acrylate, hydroxyethyl acrylate, methacrylic acid, methyl methacrylate, ethyl methacrylate, butyl methacrylate, 2-ethylhexyl methacrylate, 2-butylhexyl methacrylate, 2-dimethylaminoethyl methacrylate, hydroxyethyl methacrylate, or a copolymer containing two or more monomers.

[0027] The resin part may contain, as an additive, at least one of a thickener, a surfactant, a lubricant, a pigment, and a functional material, if necessary.

[0028] Examples of thickeners include inorganic compounds such as water-soluble alkali silicate, montmorillonite, and colloidal alumina; cellulose derivative compounds such as methyl cellulose, hydroxyethyl cellulose, and carboxymethyl cellulose; polyether compounds such as pluronic polyether, polyether dialkyl ester, polyether dialkyl ether, polyether urethane-modified product, and polyether epoxy-modified product; polyacrylic acid compounds such as sodium polyacrylate and poly(acrylic acid / (meth)acrylic acid ester) copolymer; polyvinyl compounds such as polyvinyl pyrrolidone, polyvinyl alcohol, and polyvinyl benzyl alcohol copolymer; protein derivatives such as sodium caseinate and ammonium caseinate; maleic anhydride copolymers such as partial esters of vinyl methyl ether-maleic anhydride copolymer and half esters of reaction products of allyl alcohol esters of drying oil fatty acids-maleic anhydride.

[0029] Examples of surfactants include carboxylate, sulfonate, sulfate ester salt, quaternary ammonium salt, amine salt, betaine type, polyhydric alcohol type, polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, polyoxyethylene polyoxypropylene glycol, and polyethylene glycols. Examples of inorganic particles include titanium oxide particles, zinc oxide particles, silicon dioxide particles, activated carbon particles, silver particles, and copper particles.

[0030] Examples of the lubricant include paraffin wax, synthetic polyethylene, liquid paraffin, stearic acid, behenic acid, hydroxystearic acid, stearyl alcohol, stearic acid amide, oleic acid amide, erucic acid amide, methylene bisstearic acid amide, ethylene bisstearic acid amide, glycerin monostearate, glycerin monooleate, butyl stearate, metal soap, fumed silica, etc. Examples of the pigment include alkali blue, lysol red, carmine 6B, disazo yellow, phthalocyanine blue, quinacridone red, isoindoline yellow, red clay, yellow earth, green earth, malachite, white lead, graphite, ultramarine, zinc white, cobalt blue, emerald green, viridian, titanium white, fluorescent pigment, metal powder pigment, pearl pigment, thermochromic pigment, etc.

[0031] As the functional material, those that impart additional functions such as deodorizing property, antifouling property, pest control property, antiviral property, antibacterial property, antifungal property, heat storage property, etc. to the fiber material except for suppressing the shedding of fiber fragments from the fiber substrate can be used. Examples of the functional material include metal particles, metal oxide particles (excluding composite metal oxide particles), composite metal oxide particles, activated carbon particles, pest behavior disruption inducer, organic antiviral / antibacterial / antifungal agent, etc. Examples of the metal particles include silver particles, copper particles, zinc particles, etc. Examples of the metal oxide particles include titanium oxide particles, silicon oxide particles (for example, silicon dioxide particles), zinc oxide particles, etc. Examples of the composite metal oxide particles include SiO2-ZnO composite particles, etc. Examples of the pest behavior disruption inducer include organic ester compounds. Examples of the organic ester compounds include N-(3,4,5,6-tetrahydro-phthalimide)methyl(1R)-cis / trans-chrysanthemate, 5-benzyl-3-furylmethyl-cis / trans-chrysanthemate, 3-phenoxylbenzyl(1R)-cis / trans-chrysanthemate, 3-phen xylbenzyl(1RS)-cis / trans-3-2,2-dichlorovinyl-2,2-di Methyl cyclopropanecarboxylate, (RS)-α-cyano-3-phenoxybenzyl (1R)-cis / trans-chrysanthemate, (S)-2-methyl-4-oxo-3-(2-propenyl)-2-cyclopentenyl (1R)-cis / trans-chrysanthemate, etc. and their isomers are included. Examples of organic antiviral, antibacterial, and antifungal agents include quaternary ammonium salts, pyridine-based compounds, halogenated phenols, and organic iodine.

[0032] In the case where the resin part is a thermally crosslinkable resin that crosslinks by heat, examples of the thermally crosslinkable resin include those obtained by adding an epoxy-based crosslinking agent to acrylic or polyurethane, etc., and those to which N-methylolacrylamide is added are preferred from the viewpoint of washing durability at the consumption stage.

[0033] The average diameter D of the resin part can be 0.05 to 5.00 mm. From the viewpoint of suppressing the detachment of fiber fragments from the fiber substrate, the average diameter D of the resin part may be 0.10 mm or more, 0.15 mm or more, 0.20 mm or more, 0.25 mm or more, 0.30 mm or more, 0.35 mm or more, or 0.40 mm or more.

[0034] From the viewpoint of easily obtaining an excellent texture, the average diameter D may be 5.00 mm or less, 4.00 mm or less, 3.50 mm or less, 3.00 mm or less, 2.50 mm or less, 2.00 mm or less, 1.50 mm or less, 1.20 mm or less, 1.00 mm or less, 0.80 mm or less, or 0.70 mm or less.

[0035] From these two viewpoints, the average diameter D of the resin part can be 0.05 to 5.00 mm, preferably 0.10 to 4.00 mm, more preferably 0.15 to 3.50 mm, and particularly preferably 0.30 to 3.00 mm.

[0036] The average diameter D of the resin part can be obtained by observing the resin part in the resin-coated fiber substrate using a microscope and measuring the diameter of the resin part. While changing the measurement location so that the measurement locations are distributed substantially evenly in the resin-coated fiber substrate, measure the diameters of 20 resin parts, and obtain the average value of 10 measurement values excluding the 5 measurement values counted from the maximum and the 5 measurement values counted from the minimum as the average diameter D of the resin part. When the shape of the resin part is not a perfect circle, the area of the resin part can be measured using area calculation software built into the microscope or the like, and the diameter of the perfect circle having that area can be obtained as the diameter of the resin part.

[0037] The average number (points) P of the resin parts per 1 inch (25.4 mm) can be set to 5.0 to 50.0 pieces / 25.4 mm. From the viewpoint of suppressing the detachment of fiber fragments from the fiber substrate, the average number P can be 7.5 pieces / 25.4 mm or more, 10.0 pieces / 25.4 mm or more, 12.0 pieces / 25.4 mm or more, 15.0 pieces / 25.4 mm or more, 18.0 pieces / 25.4 mm or more, 20.0 pieces / 25.4 mm or more, or 22.0 pieces / 25.4 mm or more, or 24.0 pieces / 25.4 mm or more.

[0038] From the viewpoint of improving the appearance quality of the fiber substrate, the average number P can be 48.0 pieces / 25.4 mm or less, 45.0 pieces / 25.4 mm or less, 42.0 pieces / 25.4 mm or less, or 41.0 pieces / 25.4 mm or less.

[0039] From these two viewpoints, the average number P is preferably 7.5 to 48.0 pieces / 25.4 mm, more preferably 10.0 to 45.0 pieces / 25.4 mm, and particularly preferably 12.0 to 42.0 pieces / 25.4 mm.

[0040] Incidentally, the average number P per 1 inch (25.4 mm) of the resin part can be obtained as follows. While changing the measurement locations so that the measurement locations of 25.4 mm in length and 25.4 mm in width are distributed substantially evenly in the resin-coated fiber base material, for 20 measurement locations, the number of resin parts in which all or part of the measurement location is included is measured using a stripe-viewing magnifier. The average value of 10 measurement values excluding the 5 measurement values counted from the maximum and the 5 measurement values counted from the minimum is obtained, and the square root thereof can be obtained as the average number P per 1 inch (25.4 mm) of the resin part. Here, when the size of the resin-coated fiber base material is small and 20 measurement locations cannot be secured, or when the number of resin parts included in the measurement locations of 25.4 mm in length and 25.4 mm in width is large and measurement is difficult, after appropriately adjusting the size of the measurement location, it may be proportionally adjusted to an area of 25.4 mm × 25.4 mm. Further, when it is difficult to measure the resin part of the measurement location with an appropriately adjusted size using a stripe-viewing magnifier, the resin part may be measured using a known microscope.

[0041] The lower the numerical value of the product (D × P) of the average diameter D and the average number P, the lower the visibility of the dot-shaped resin part. That is, the higher the appearance quality of the resin-coated fiber base material, the lower the numerical value of D × P. From the viewpoint of not making the user feel the presence of the resin part formed on the resin-coated fiber base material, D × P can be 16.0 or less, 15.5 or less, 15.0 or less, 12.5 or less, 10.0 or less, 8.0 or less, 7.5 or less, 5.0 or less, 4.0 or less, 3.0 or less, preferably 16.0 or less, more preferably in the range of 2.0 to 16.0, even more preferably in the range of 3.0 to 15.5, and particularly preferably in the range of 4.0 to 15.0.

[0042] On the one hand, the higher the value of the product (D×P) of the average diameter D and the average number P, the higher the visibility of the dot-shaped resin part. That is, although the appearance quality of the resin-attached fiber base material deteriorates as the value of D×P increases, from the viewpoint of efficiently obtaining suppression of fiber fragment detachment, D×P can be set to be more than 16.0, 16.5 or more, 17.0 or more, 20.0 or more, 22.5 or more, 25.0 or more, 27.5 or more, 30.0 or more. It is preferably more than 16.0, more preferably in the range of 16.5 to 30.0, and even more preferably in the range of 17.0 to 27.5.

[0043] The resin part attached to at least one surface of the resin-attached fiber base material is arranged such that the average diameter D of the resin part, the average number P of the resin part, and the average twist number T of the spun yarn satisfy the following formula (1). 8.6≦[D / {25.4 / (P - 1)}]×P / T≦61.2 ···(1) Hereinafter, in some cases, the numerical value represented by "[D / {25.4 / (P - 1)}]×P / T" will be referred to as "parameter X".

[0044] The technical significance of parameter X will be explained. Let the numerical value represented by "25.4 / (P - 1)", which is a part of parameter X, be "parameter Xa". Parameter Xa indicates the theoretical upper limit value of the center - to - center distance between adjacent resin parts. Let the numerical value "D / (25.4 / (P - 1))" obtained by dividing the average diameter D by parameter Xa be "parameter Xb". Such parameter Xb indicates the ratio of the average diameter of the resin parts actually provided on the fiber base material to the theoretical upper limit value of the center - to - center distance between adjacent resin parts. That is, parameter Xb indicates the force by which one resin part provided on the fiber base material restrains the spun yarn. It can be understood that the greater the value of parameter Xb, the greater the force by which one resin part provided on the fiber base material restrains the spun yarn.

[0045] The value "D / (25.4 / (P - 1))×P" obtained by multiplying the parameter Xb by the average number P per inch (25.4 mm) is defined as the "parameter Xc". That is, the parameter Xc indicates the force with which all the resin parts provided on the fiber base material restrain the spun yarn. It can be seen that the greater the value of the parameter Xc, the greater the force with which all the resin parts provided on the fiber base material restrain the spun yarn.

[0046] When the value of the parameter Xc increases, the restraining force of the resin part on the spun yarn increases, so there is a tendency that it becomes easier to suppress the shedding of microfibers. On the other hand, when the value of the parameter Xc increases, the texture of the fiber base material tends to deteriorate. Also, when the average twist number T of the spun yarn increases, the performance of suppressing the shedding of microfibers possessed by the spun yarn itself is enhanced. For this reason, there is a tendency that the effect of suppressing the shedding of microfibers by the resin part is relatively reduced. The parameter X shows the balance of these tendencies.

[0047] From the viewpoint of being able to suppress the shedding of fiber fragments from the fiber base material, the above-mentioned parameter X may be 8.6 or more, 10.0 or more, 15.7 or more, 20.0 or more, 25.0 or more, or 30.0 or more.

[0048] From the viewpoint of easily obtaining an excellent texture, the parameter X may be 61.2 or less, 50.0 or less, 45.0 or less, 40.0 or less, 38.2 or less, or 37.5 or less, 23.0 or less, 20.0 or less, 15.0 or less, 13.0 or less, or 10.0 or less. From these two viewpoints, the parameter X can be set to 8.6 to 61.2, preferably 15.7 to 38.2, and more preferably 31.3 to 36.4.

[0049] The above-mentioned resin-coated fiber base material can be applied to, for example, fabrics used for clothing, fabrics used for living materials such as bed covers and sheets.

[0050] The anti-shedding method according to this embodiment is an anti-shedding method for suppressing a part of synthetic fibers from shedding from a fiber substrate having a spun yarn formed including synthetic fibers. The anti-shedding method according to this embodiment includes a resin part forming step of forming dot-shaped resin parts having an average diameter D in the range of 0.05 to 5.00 mm and an average number P per inch in the range of 5.0 to 50.0 pieces / 25.4 mm on at least one surface of a fiber substrate having a spun yarn with an average twist number T in the range of 0.10 to 3.00 turns / mm. The resin part forming step of the anti-shedding method according to this embodiment forms the average diameter D and the average number P of the resin parts so as to satisfy the following formula (3). 8.6 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 61.2 ···(3) Note that the numerical value of "[D / {25.4 / (P - 1)}]×P / T" in the above formula (3) is the same as the above "parameter X".

[0051] According to the anti-shedding method according to this embodiment, the shedding improvement rate, which will be described in detail later, can be increased. According to the anti-shedding method according to this embodiment, a shedding improvement rate of 10% or more can be achieved. According to the anti-shedding method according to this embodiment, a good texture can be provided. For example, according to the anti-shedding method according to this embodiment, in the evaluation method described in the examples below, an evaluation of "B" or higher can be given. Also, according to the anti-shedding method according to this embodiment, a good appearance quality can be provided. For example, according to the anti-shedding method according to this embodiment, in the evaluation method described in the examples below, an evaluation of "B" or higher can be given.

[0052] According to one aspect of the anti-shedding method according to this embodiment, the average diameter D, the average number P, and the average twist number T can satisfy the following formula (4). 15.7 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 38.2 ···(4) According to one aspect of the dropout suppression method according to this embodiment, a dropout improvement rate of 30% or more can be achieved. According to the dropout suppression method according to this embodiment, a good texture can be provided. For example, according to the dropout suppression method according to this embodiment, in the evaluation method described in the examples below, an evaluation of "A" or higher can be given.

[0053] According to one aspect of the dropout suppression method according to this embodiment, the average diameter D, the average number P, and the average twist number T can satisfy the following formula (2-1). 31.3 ≦ [D / {25.4 / (P - 1)}]×P / T ≦ 36.4 ···(4-1) According to one aspect of the dropout suppression method according to this embodiment, a dropout improvement rate of 35% or more can be achieved. According to the resin-coated fiber base material according to this embodiment, a good texture can be obtained. For example, according to the dropout suppression method according to this embodiment, in the evaluation method described in the examples below, an evaluation of "A" or higher can be given.

Examples

[0054] Hereinafter, one aspect of the present invention will be described more specifically by way of examples and comparative examples, but one aspect of the present invention is not limited to the following examples.

[0055] <Production of Resin-Coated Woven Fabric for Evaluation> (Example 1) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist number was 0.47 turns / mm, thereby obtaining a spun yarn with an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Example 1, this spun yarn was used to weave a plain weave and subjected to a dyeing finish to obtain Evaluation Fabric 1 with 85 warp ends / 25.4 mm and 70 weft picks / 25.4 mm.

[0056] On one side of the evaluation fabric 1, resin portions were arranged in a dot pattern to form the evaluation fabric 1 with resin. Specifically, dot-shaped paste that would become the resin portions was transferred onto one side of the evaluation fabric 1 using a rotary screen with adjusted pitch and opening diameter. The resin portions were formed mainly using a resin made from NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Kogyo Co., Ltd. The average diameter D of the resin portions was 0.50 mm, the number P of resin portions per 1 inch (25.4 mm) was 30.0, and the product (D × P) of the average diameter D and the number P of resin portions was 15.0.

[0057] (Example 2) The polyester staple fibers were spun using a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist number was 0.47 turns / mm, thereby obtaining a spun yarn 2 with an average fineness of 197 dtex and a twist of 0.47 turns / mm applied. In Example 2, this spun yarn 2 was used as the warp and weft to perform plain weaving and dyeing finishing, thereby obtaining an evaluation fabric 2 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0058] On one side of the evaluation fabric 2, resin portions were arranged in a dot pattern to form the evaluation fabric 2 with resin adhered. Specifically, dot-shaped paste that would become the resin portions was transferred onto one side of the evaluation fabric 2 using a rotary screen with adjusted pitch and opening diameter. The resin portions were formed mainly using a resin made from NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Kogyo Co., Ltd. The average diameter D of the resin portions was 0.20 mm, the number P of resin portions per 1 inch (25.4 mm) was 40.0, and the product (D × P) of the average diameter D and the number P of resin portions was 8.0.

[0059] (Example 3) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.94 turns / mm, thereby obtaining a spun yarn 3 with an average fineness of 197 dtex and a twist of 0.94 turns / mm. In Example 3, this spun yarn 3 was used as the warp and weft to perform plain weaving and dyeing finishing, thereby obtaining an evaluation fabric 3 with a warp weave density of 85 threads / 25.4 mm and a weft weave density of 70 threads / 25.4 mm.

[0060] On one surface of the evaluation fabric 3, resin portions were arranged in a dot shape to form an evaluation resin-attached fabric 3. Specifically, a dot-shaped paste that would become the resin portion was transferred to one surface of the evaluation fabric 3 using a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portion was 0.50 mm, the number P of resin portions per 1 inch (25.4 mm) was 30.0, and the product (D×P) of the average diameter D and the number P of resin portions was 15.0.

[0061] (Example 4) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 4 with an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Example 4, this spun yarn 4 was used as the warp and weft to perform plain weaving and dyeing finishing, thereby obtaining an evaluation fabric 4 with a warp weave density of 85 threads / 25.4 mm and a weft weave density of 70 threads / 25.4 mm.

[0062] On one side of the evaluation fabric 4, resin portions were arranged in a dot pattern to form an evaluation resin - attached fabric 4. Specifically, a dot - shaped paste that would become the resin portion was transferred onto one side of the evaluation fabric 4 using a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT - 094 (acrylic emulsion) manufactured by Nitto Chemical Industry Co., Ltd. The average diameter D of the resin portion was 2.00 mm, the number P of resin portions per 1 inch (25.4 mm) was 12.5, and the product of the average diameter D and the number P of resin portions (D×P) was 25.0.

[0063] (Example 5) The polyester staple fiber was spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist number was 0.24 turns / mm, thereby obtaining a spun yarn 5 with an average fineness of 197 dtex and a twist of 0.24 turns / mm applied. In Example 5, this spun yarn 5 was used as the warp and weft to perform a plain weave, followed by a dyeing finish, to obtain an evaluation fabric 5 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0064] On one side of the evaluation fabric 5, resin portions were arranged in a dot pattern to form an evaluation resin - attached fabric 5. Specifically, a dot - shaped paste that would become the resin portion was transferred onto one side of the evaluation fabric 5 using a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT - 094 (acrylic emulsion) manufactured by Nitto Chemical Industry Co., Ltd. The average diameter D of the resin portion was 2.00 mm, the number P of resin portions per 1 inch (25.4 mm) was 8.5, and the product of the average diameter D and the number P of resin portions (D×P) was 17.0.

[0065] (Example 6) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 6 with an average fineness of 197 dtex and a twist of 0.47 turns / mm applied thereto. In Example 6, this spun yarn 6 was used as the warp and weft to perform plain weaving and then dyeing finishing, thereby obtaining an evaluation fabric 6 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0066] On one surface of the evaluation fabric 6, resin portions were arranged in a dot shape to form an evaluation resin-attached fabric 6. Specifically, a dot-shaped paste that would become the resin portion was transferred to one surface of the evaluation fabric 6 using a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made of NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Kogyo Co., Ltd. The average diameter D of the resin portion was 2.00 mm, the number P of resin portions per 1 inch (25.4 mm) was 8.5, and the product (D × P) of the average diameter D and the number P of resin portions was 17.0.

[0067] (Example 7) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 7 with an average fineness of 197 dtex and a twist of 0.47 turns / mm applied thereto. In Example 7, this spun yarn 7 was used as the warp and weft to perform plain weaving and then dyeing finishing, thereby obtaining an evaluation fabric 7 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0068] On one surface of the evaluation fabric 7, resin portions were arranged in a dot pattern to form an evaluation resin - attached fabric 7. Specifically, a dot - shaped paste that would become the resin portion was transferred onto one surface of the evaluation fabric 7 by a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT - 094 (acrylic emulsion) manufactured by Nitto Chemical Industry Co., Ltd. The average diameter D of the resin portion was 0.10 mm, the number P of resin portions per 1 inch (25.4 mm) was 40.0, and the product (D×P) of the average diameter D and the number P of resin portions was 4.0.

[0069] (Example 8) Polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist number was 0.47 turns / mm, thereby obtaining a spun yarn 8 with an average fineness of 197 dtex and a twist of 0.47 turns / mm applied. In Example 8, this spun yarn 8 was used as the warp and weft to perform plain weaving and then dyeing finishing, obtaining an evaluation fabric 8 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0070] On one surface of the evaluation fabric 8, resin portions were arranged in a dot pattern to form an evaluation resin - attached fabric 8. Specifically, a dot - shaped paste that would become the resin portion was transferred onto one surface of the evaluation fabric 8 by a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT - 094 (acrylic emulsion) manufactured by Nitto Chemical Industry Co., Ltd. The average diameter D of the resin portion was 1.40 mm, the number P of resin portions per 1 inch (25.4 mm) was 19.0, and the product (D×P) of the average diameter D and the number P of resin portions was 26.6.

[0071] (Comparative Example 1) The polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 11 with an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Comparative Example 1, this spun yarn 11 was used as the warp and weft to perform plain weaving and dyeing finishing, thereby obtaining an evaluation fabric 11 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0072] On one side of the evaluation fabric 11, resin portions were arranged in a dot shape to form an evaluation resin-attached fabric 11. Specifically, a dot-shaped paste that would become the resin portion was transferred onto one side of the evaluation fabric 11 using a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made of NIT-094 (acrylic emulsion) manufactured by Nitto Chemical Industry Co., Ltd. The average diameter D of the resin portion was 0.10 mm, the number P of resin portions per 1 inch (25.4 mm) was 17.0, and the product (D × P) of the average diameter D and the number P of resin portions was 1.7.

[0073] (Comparative Example 2) The polyester staple fibers were spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 12 with an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Comparative Example 2, this spun yarn 12 was used as the warp and weft to perform plain weaving and dyeing finishing, thereby obtaining an evaluation fabric 12 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0074] On one side of the evaluation fabric 12, resin portions were arranged in a dot pattern to form the resin-attached evaluation fabric 12. Specifically, a dot-shaped paste that would become the resin portion was transferred to one side of the evaluation fabric 12 using a rotary screen with adjusted pitch and aperture diameter. The resin portion was formed using a resin mainly made from NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Co., Ltd. The average diameter D of the resin portion was 0.60 mm, the number P of resin portions per 1 inch (25.4 mm) was 7.0, and the product (D×P) of the average diameter D and the number P of resin portions was 4.2.

[0075] (Comparative Example 3) The polyester staple fibers were spun using a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist number was 0.94 turns / mm, to obtain a spun yarn 13 with an average fineness of 197 dtex and a twist of 0.94 turns / mm applied. In Comparative Example 3, this spun yarn 13 was used as the warp and weft to perform plain weaving and then dyeing finishing, to obtain an evaluation fabric 13 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0076] On one side of the evaluation fabric 13, resin portions were arranged in a dot pattern to form the resin-attached evaluation fabric 13. Specifically, a dot-shaped paste that would become the resin portion was transferred to one side of the evaluation fabric 13 using a rotary screen with adjusted pitch and aperture diameter. The resin portion was formed using a resin mainly made from NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Co., Ltd. The average diameter D of the resin portion was 0.10 mm, the number P of resin portions per 1 inch (25.4 mm) was 40.0, and the product (D×P) of the average diameter D and the number P of resin portions was 4.0.

[0077] (Comparative Example 4) The polyester staple fiber was spun on a known spinning machine while adjusting the spindle and torque so that the average fineness was 197 dtex and the average twist was 0.47 turns / mm, thereby obtaining a spun yarn 14 with an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Comparative Example 4, this spun yarn 14 was used as the warp and weft yarns to perform plain weaving and then dyeing finishing, thereby obtaining an evaluation fabric 14 with a warp weaving density of 85 threads / 25.4 mm and a weft weaving density of 70 threads / 25.4 mm.

[0078] On one surface of the evaluation fabric 14, resin portions were arranged in a dot shape to form an evaluation resin-attached fabric 14. Specifically, a dot-shaped paste that would become the resin portion was transferred onto one surface of the evaluation fabric 14 by a rotary screen with adjusted pitch and opening diameter. The resin portion was formed using a resin mainly made from NIT-094 (acrylic emulsion) manufactured by Nitto Kasei Kogyo Co., Ltd. The average diameter D of the resin portion was 0.60 mm, the number P of resin portions per 1 inch (25.4 mm) was 41.0, and the product (D×P) of the average diameter D and the number P of resin portions was 24.6.

[0079] Summarizing the average diameter D, the number P of resin portions, D×P, and the average twist T of Examples 1 to 8 and Comparative Examples 1 to 4, it is as shown in Table 1 below.

Table 1

[0080] Next, for each of the evaluation resin-attached fabrics of Examples 1 to 8 and Comparative Examples 1 to 4, for the resin portions attached to one surface of the evaluation resin-attached fabric, the above parameter X defined from the average diameter D, the average number P, and the average twist T was calculated. Also, for each of the evaluation resin-attached fabrics of Examples 1 to 8 and Comparative Examples 1 to 4, the improvement rate of fiber fragment shedding, the texture, and the appearance quality were evaluated. These evaluation results are shown in Table 2 below.

Table 2

[0081] Hereinafter, the method for calculating the improvement rate of fiber fragment shedding, the method for evaluating the texture of the resin-coated fabric, and the method for evaluating the appearance quality of the resin-coated fiber substrate will be described in order.

[0082] <Method for Calculating Improvement Rate of Fiber Fragment Shedding> Evaluation fabrics (Evaluation Fabrics 1 to 8, 11 to 14) and evaluation resin-coated fabrics (Evaluation Resin-Coated Fabrics 1 to 8, 11 to 14) in which dot-shaped resin parts are provided on the evaluation fabrics were each prepared. For example, Evaluation Resin-Coated Fabric 1 is obtained by providing dot-shaped resin parts on Evaluation Fabric 1. In other words, if the dot-shaped resin parts are removed from Evaluation Resin-Coated Fabric 1, it becomes Evaluation Fabric 1. Next, four pieces each with a size of 17 cm in length and 10 cm in width were cut out from each of these evaluation resin-coated fabrics and evaluation fabrics, and their peripheries were sewn in by 1.25 cm each to create four samples each with a final finished size of 12 cm in length and 5 cm in width.

[0083] Next, one sample of the above evaluation resin-coated fabric and 25 stainless steel balls were placed in the pot of the washing machine for colorfastness testing, and 150 ml of purified water was poured in. Note that no detergent was added to this pot. Next, the pot was covered, the bath temperature was adjusted to 40°C, and washing treatment was performed 10 times at 30 minutes per time. Then, after performing the 10 washing treatments, the waste liquid was suction-filtered, and the amount of fiber fragment shedding was measured. The amount of fiber fragment shedding was also measured for the remaining three samples of the above evaluation resin-coated fabric in the same manner. And the average amount of fiber fragment shedding in the four samples of the above evaluation resin-coated fabric was used as the "amount of fiber fragment shedding in the evaluation resin-coated fabric" for calculating the improvement rate of fiber fragment shedding described later.

[0084] Also, for each of the four samples of the evaluation fabric, the amount of fiber fragment shedding was measured by the above method, and the average amount of fiber fragment shedding in the four samples of the evaluation fabric was used as the "amount of fiber fragment shedding in the evaluation fabric" for calculating the improvement rate of fiber fragment shedding described below.

[0085] The improvement rate of fiber fragment shedding is calculated as shown in the following formula (5) based on the amount of fiber fragment shedding in the evaluation fabric and the amount of fiber fragment shedding in the evaluation fabric. Improvement rate of shedding = (Amount of fiber fragment shedding in the evaluation fabric - Amount of fiber fragment shedding in the resin - attached fabric for evaluation) / Amount of fiber fragment shedding in the evaluation fabric ··· (5)

[0086] <Evaluation of the texture of the resin - attached fabric> The evaluation of the texture was carried out by sensory evaluation by five experts. The evaluation criteria are one of A, B, and C. Each judgment criterion is as follows. Judgment criterion A: When all five out of five people judged that there was no difference in texture when comparing the above - mentioned resin - attached fabrics for evaluation 1 - 8, 11 - 14 with the corresponding evaluation fabrics 1 - 8, 11 - 14. Judgment criterion B: When four or more out of five people judged that there was no difference in texture or the texture difference was felt but acceptable when comparing the above - mentioned resin - attached fabrics for evaluation 1 - 8, 11 - 14 with the corresponding evaluation fabrics 1 - 8, 11 - 14 (excluding cases corresponding to judgment criterion A). Judgment criterion C: When two or more out of five people judged that the texture difference was significant and not an acceptable texture as clothing when comparing the above - mentioned resin - attached fabrics for evaluation 1 - 8, 11 - 14 with the corresponding evaluation fabrics 1 - 8, 11 - 14.

[0087] <Evaluation of the appearance quality of the resin - attached fabric> The evaluation of the appearance quality was based on whether five evaluators with normal vision could visually recognize the dot - shaped resin parts formed on the resin - attached fabrics for evaluation. Judgment criterion A: When 4 or more out of 5 people judge that they can easily visually recognize the dot-shaped resin part, that is, when it is judged that the appearance quality is excellent Judgment criterion B: When 2 or more out of 5 people judge that it is difficult to visually recognize the dot-shaped resin part and that confirmation at a very close distance or using a magnifying glass etc. is necessary, that is, when it is judged that the appearance quality is inferior

[0088] Although one embodiment has been described above, one aspect of the present invention is not limited to the above embodiment. Various changes are possible without departing from the gist of the invention.

[0089] In the above embodiment, the case where the resin part is formed only on one surface of the resin-attached fiber base material has been described as an example, but it may be formed on both surfaces of the resin-attached fiber base material. In this case, the average number P of resin parts is calculated based on the sum of the number of resin parts formed on the front surface of the fiber base material and the number of resin parts formed on the back surface of the fiber base material.

Claims

1. A fiber substrate having a spun yarn formed by including synthetic fibers, and Dot-shaped resin portions provided on at least one surface of the fiber substrate, comprising: The average twist number T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, The average diameter D of the resin portion is in the range of 0.05 to 5.00 mm, The average number P per inch of the resin portion is in the range of 5.0 to 50.0 pieces / 25.4 mm, The resin-attached fiber substrate in which the average diameter D and the average number P of the resin portion are provided on the fiber substrate so as to satisfy the following formula (1). 8.6 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 61.2... (1)

2. The resin-attached fiber substrate according to claim 1, wherein the average diameter D and the average number P of the resin portion satisfy the following formula (2). 15.7 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 38.2... (2)

3. A drop suppression method for suppressing a part of the synthetic fibers from dropping off from a fiber substrate having a spun yarn formed by including synthetic fibers, On at least one surface of the fiber substrate having the spun yarn with an average twist number T in the range of 0.10 to 3.00 turns / mm, a dot-shaped resin portion having an average diameter D in the range of 0.05 to 5.00 mm and an average number P per inch in the range of 5.0 to 50.0 pieces / 25.4 mm is formed, including a resin portion forming step, The resin portion forming step forms the average diameter D and the average number P of the resin portion so as to satisfy the following formula (3). A drop suppression method. 8.6 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 61.2... (3)

4. The drop suppression method according to claim 3, wherein the resin portion forming step forms the average diameter D and the average number P of the resin portion so as to satisfy the following formula (3). 15.7 ≦ [D / {25.4 / (P - 1)}] × P / T ≦ 38.2... (4)

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