Resin-adhered fiber base material and falling-off suppression method

Abstract

The present invention addresses the problem of providing a resin-attached fiber base material which suppresses falling of a fiber fragment (a part of synthetic fiber) from a fiber base material and is excellent in texture, and to provide a falling-off suppression method.　A resin-attached fiber base material according to the present invention comprises: a fiber base material having a spun yarn formed including synthetic fibers; and a dot-like resin part 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 0.10-3.00 turns / mm, the average diameter D of the resin part is in the range of 0.05-5.00 mm, the average number P per inch of the resin part is in the range of 5.0-50.0 pieces / 25.4 mm, and the average diameter D and the average number P of the resin part are provided on the fiber base material so as to satisfy formula (1) below. Formula (1): 8.6 ≤ [D / 25.4 / (P-1) } ] × P / T ≤ 61.2

Description

Resin-adhered fiber substrate and method for preventing shedding

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

[0002] In recent years, there has been growing interest in environmental pollution caused by microplastics. In light of this, there is a need to prevent fiber fragments (microfibers), a type of microplastic, from falling off from textile products having spun yarns containing synthetic fibers when the textile products are washed. For example, Patent Document 1 below describes a method for preventing the generation of fluff when the textile substrate is washed by providing dot-shaped resin portions on at least one surface of the textile substrate.

[0003] Japanese Patent Application Laid-Open No. 2004-115945

[0004] However, since fuzz is generated on the surface of a fiber substrate after the fact, methods for suppressing the generation of such fuzz cannot prevent some of the synthetic fibers (i.e., fiber fragments) from falling off from the fiber substrate when the fiber substrate is made of a spun yarn containing synthetic fibers. Therefore, it is conceivable to suppress the falling off of fiber fragments by coating the entire surface of the fiber substrate with a resin, but in this case, it is conceivable that the texture of the fiber product will be deteriorated.

[0005] Therefore, an object of one aspect of the present invention is to provide a resin-adhered fibrous substrate and a method for preventing fiber fragments from falling off from the fibrous substrate and having an excellent texture.

[0006] [1] A resin-adhered fiber substrate according to one aspect of the present invention comprises a fiber substrate having a spun yarn formed from synthetic fibers, and dot-shaped resin portions provided on at least one surface of the fiber substrate, wherein 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 portions is in the range of 0.05 to 5.00 mm, and the average number P of the resin portions per inch is in the range of 5.0 to 50.0 portions / 25.4 mm, and the average diameter D and 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)

[0007] In this configuration, in a resin-adhered fibrous substrate in which 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 portions / 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 portions are provided so that the average diameter D and the average number P satisfy the above formula (1). This prevents fiber fragments from falling off from the fibrous substrate, and allows for a resin-adhered fibrous substrate with excellent texture.

[0008] [2] In the resin-adhered fibrous substrate according to [1], the average diameter D and average number P of the resin portions may satisfy the following formula (2): 15.7≦[D / {25.4 / (P−1)}]×P / T≦38.2 (2) This further suppresses fiber fragments from falling off from the fibrous substrate, and allows the resin-adhered fibrous substrate to have an even more excellent texture.

[0009] [3] A shedding suppression method according to one aspect of the present invention is a shedding suppression method for suppressing shedding of some synthetic fibers from a fiber substrate having a spun yarn formed containing synthetic fibers, the method comprising a resin portion forming step of forming dot-shaped resin portions having an average diameter D of 0.05 to 5.00 mm and an average number P per inch in the range of 5.0 to 50.0 / 25.4 mm on at least one surface of the fiber substrate having a spun yarn with an average twist number T in the range of 0.10 to 3.00 turns / mm, wherein the resin portion forming step forms the average diameter D and average number P of the resin portions so as to satisfy the following formula (3): 8.6≦[D / {25.4 / (P−1)}]×P / T≦61.2 (3)

[0010] This method includes a resin portion forming step in which, in a resin-adhered fibrous substrate having an average diameter D of the resin portions in the range of 0.05 to 5.00 mm, an average number P of the resin portions per inch in the range of 5.0 to 50.0 portions / 25.4 mm, and an average twist number T of the spun yarn in the range of 0.10 to 3.00 turns / mm, the resin portions are provided so that the average diameter D and the average number P satisfy the above formula (1). This prevents fiber fragments from falling off from the fibrous substrate, and allows for a resin-adhered fibrous substrate with excellent texture.

[0011] [4] In the method for preventing falling off according to [3], the resin portion forming step may form the resin portions with an average diameter D and an average number P so as to satisfy the following formula (4): 15.7≦[D / {25.4 / (P−1)}]×P / T≦38.2 (4).

[0012] According to one aspect of the present invention, it is possible to provide a resin-coated fibrous substrate that is inhibited from causing fiber fragments to fall off from the fibrous substrate and that has an excellent feel.

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

[0014] In this specification, a numerical range indicated using "to" indicates a range that includes the numerical values ​​before and after "to" as the minimum and maximum values, respectively. In the numerical ranges described in stages in this specification, the upper or lower limit of a numerical range of a certain stage can be arbitrarily combined with the upper or lower limit of a numerical range of another stage. In the numerical ranges described in this specification, the upper or lower limit of the numerical range may be replaced with a value shown in the examples. "A or B" may include either A or B, or may include both. Unless otherwise specified, the materials exemplified in this specification can be used alone or in combination of two or more types. The term "step" does not only refer to an independent step, but also includes a step that cannot be clearly distinguished from other steps as long as the intended effect of the step is achieved.

[0015] The resin-adhered fibrous substrate according to this embodiment includes a fibrous substrate having a spun yarn formed from synthetic fibers, and dot-shaped resin portions provided on at least one surface of the fibrous substrate. In the resin-adhered fibrous substrate 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 portions / 25.4 mm, and the average twist T of the spun yarn is in the range of 0.10 to 3.00 turns / mm, with the average diameter D, average number P, and average twist T satisfying the following formula (1): 8.6≦[D / {25.4 / (P-1)}]×P / T≦61.2 (1) Hereinafter, the value of "[D / {25.4 / (P-1)}]×P / T" will sometimes be referred to as "parameter X."

[0016] The resin-adhered fibrous substrate according to this embodiment can increase the improvement rate with respect to fiber fragment shedding (hereinafter referred to as "shedding improvement rate"), which will be described in detail later. The resin-adhered fibrous substrate according to this embodiment can achieve a shedding improvement rate of 10% or more. The resin-adhered fibrous substrate according to this embodiment can obtain a good texture. For example, the resin-adhered fibrous substrate according to this embodiment can obtain a rating of "B" or higher in the evaluation method described in the examples below. Furthermore, the resin-adhered fibrous substrate according to this embodiment can obtain good appearance quality. For example, the resin-adhered fibrous substrate according to this embodiment can obtain a rating of "B" or higher in the evaluation method described in the examples below.

[0017] According to one aspect of the resin-adhered fibrous substrate of this embodiment, the average diameter D, average number P, and 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-adhered fibrous substrate of this embodiment, a dropout improvement rate of 30% or more can be achieved. The resin-adhered fibrous substrate of this embodiment can provide a good texture. For example, the resin-adhered fibrous substrate of this embodiment can provide an evaluation of "A" or higher in the evaluation method described in the examples below.

[0018] According to one aspect of the resin-adhered fibrous substrate of this embodiment, the average diameter D, average number P, and 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-adhered fibrous substrate of this embodiment, a dropout improvement rate of 35% or more can be achieved. The resin-adhered fibrous substrate of this embodiment can provide a good texture. For example, the resin-adhered fibrous substrate of this embodiment can be evaluated as "A" or higher in the evaluation method described in the examples below.

[0019] The fiber substrate may be a fiber woven fabric from the viewpoint of easily obtaining excellent processability. The weave of the fiber woven fabric is not particularly limited. Examples of the weave of the fiber woven fabric include a plain weave, a twill weave, a satin weave, and a rib weave. The weave of the fiber woven fabric may be a plain weave or a twill weave from the viewpoint of easily performing processing to provide a resin portion. The weave of the fiber woven fabric may be a multiple weave such as a double weave (biaxial weave) or a triple weave. The weave of the fiber woven fabric may be a varied weave such as a basket weave or a rib weave. The weave of the fiber woven fabric may be a special weave such as a twill weave or a sand weave. The weave of the fiber woven fabric may be another weave. The fiber substrate may be a fiber knit.

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

[0021] The spun yarn containing synthetic fibers may be formed from a single yarn or multiple yarns. When the spun yarn is formed from multiple yarns, the number of yarns may be three or less, and from the viewpoint of the balance between the texture and strength of the yarn, it is preferable to have two or less yarns.

[0022] The average twist number T of the spun yarn constituting the fiber base material can be 0.10 to 3.00 turns / mm. Considering the ability to prevent fiber fragments from falling off from the fiber base material, the average twist number T of the spun yarn 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, 0.35 turns / mm or more, or 0.40 turns / mm or more, preferably 0.25 turns / mm or more, and more preferably 0.35 turns / mm or more.

[0023] Furthermore, from the viewpoint of softening the texture of the spun yarn, the average twist number T of the spun yarn constituting the fiber base material may 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 yarn can be measured by the following method. 20 spun yarns are extracted from the warp yarns of the resin-attached fibrous substrate, and the twist number of the resulting 20 spun yarns is measured in accordance with "JIS L 1095:2010 Measurement of twist number." The average of 10 measurements, excluding the five largest and five smallest measurements, is taken as the average twist number of the warp spun yarn. 20 spun yarns are extracted from the weft yarns of the resin-attached fibrous substrate, and the average twist number of the weft spun yarn is determined in the same manner as for the warp yarn. The average twist number T of the spun yarn is the average of the average twist number of the warp spun yarn and the average twist number of the weft spun yarn. Note that if the warp or weft does not contain a spun yarn and the average twist number of the warp spun yarn or the average twist number of the weft spun yarn cannot be determined, the average twist number T of the spun yarn is taken as the average twist number of the weft spun yarn or the average twist number of the warp spun yarn.

[0025] A resin portion is attached to the fiber substrate. The resin portion is provided in the form of dots on at least one surface of the fiber substrate. The resin portion may be attached to only one surface of the fiber substrate, or may be attached to both surfaces of the fiber substrate. "Dot-like" usually means that a plurality of circular (approximately circular (including perfect circles) or approximately elliptical) dots are regularly arranged, but the shape or arrangement of each dot is not particularly limited. For example, the shape of each dot may be a square, hexagon, star, etc. Alternatively, each dot may be irregularly arranged.

[0026] If the resin forming the resin portion can be fixed to the surface of the fiber substrate containing the spun yarn, it can prevent fiber fragments from falling off the fiber substrate. Therefore, known printing binder resins for fiber substrates can be used as the resin forming the resin portion. Examples of resins that can form such resin portions include thermoplastic resins and curable resins that are cured by heat and ultraviolet light. More specifically, examples of resins that can form the resin portion include polyurethane, acrylic, polyamide, polyester, polyolefin, vinyl acetate, epoxy, silicone resin, and polyvinyl alcohol-based resins. Acrylic resins are particularly preferred because of their good water resistance and low cost. Examples of acrylic resins include homopolymers containing any one of the following monomers: 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, and hydroxyethyl methacrylate, or copolymers containing two or more of these monomers.

[0027] The resin portion may contain at least one of a thickener, a surfactant, a lubricant, a pigment, and a functional material as an additive, 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, modified polyether urethane, and modified polyether epoxy; polyacrylic acid compounds such as sodium polyacrylate and polyacrylic acid (meth)acrylic acid ester copolymer; polyvinyl compounds such as polyvinylpyrrolidone, polyvinyl alcohol, and polyvinylbenzyl alcohol copolymer; protein derivatives such as sodium caseinate and ammonium caseinate; and maleic anhydride copolymers such as partial esters of vinyl methyl ether-maleic anhydride copolymers and half esters of reaction products of drying oil fatty acid allyl alcohol esters and maleic anhydride.

[0029] Examples of surfactants include carboxylates, sulfonates, sulfates, quaternary ammonium salts, amine salts, betaine-type surfactants, polyhydric alcohol-type surfactants, polyoxyethylene alkyl ethers, polyoxyethylene alkylphenyl ethers, polyoxyethylene polyoxypropylene glycols, polyethylene glycols, etc. Examples of inorganic particles include titanium oxide particles, zinc oxide particles, silicon dioxide particles, activated carbon particles, silver particles, copper particles, etc.

[0030] Examples of lubricants include paraffin wax, synthetic polyethylene, liquid paraffin, stearic acid, behenic acid, hydroxystearic acid, stearyl alcohol, stearamide, oleamide, erucamide, methylenebisstearamide, ethylenebisstearamide, glycerin monostearate, glycerin monooleate, butyl stearate, metal soap, fumed silica, etc. Examples of pigments include alkali blue, lysol red, carmine 6B, disazo yellow, phthalocyanine blue, quinacridone red, isoindoline yellow, red earth, yellow ochre, green earth, malachite, chalk, graphite, iron blue, zinc white, cobalt blue, emerald green, viridian, titanium white, fluorescent pigments, metal powder pigments, pearl pigments, thermochromic pigments, etc.

[0031] The functional material can be one that imparts additional functions to the fiber material, such as deodorizing, stain-resistant, pest-resistant, antiviral, antibacterial, antifungal, and heat storage properties, in addition to inhibiting shedding of fiber fragments from the fiber substrate. Examples of functional materials include metal particles, metal oxide particles (excluding composite metal oxide particles), composite metal oxide particles, activated carbon particles, pest behavior distractors, and organic antiviral, antibacterial, and antifungal agents. Examples of metal particles include silver particles, copper particles, and zinc particles. Examples of metal oxide particles include titanium oxide particles, silicon oxide particles (e.g., silicon dioxide particles), and zinc oxide particles. Examples of composite metal oxide particles include SiO2-ZnO composite particles. Examples of pest behavior distractors include organic ester compounds. Examples of organic ester compounds include N-(3,4,5,6-tetrahydrophthalimido)methyl (1R)-cis / trans-chrysanthemate, 5-benzyl-3-furylmethyl-cis / trans-chrysanthemate, 3-phenoxylbenzyl (1R)-cis / trans-chrysanthemate, 3-phenoxylbenzyl (1RS)-cis / trans-3-2,2-dichlorovinyl-2,2-dimethylcyclopropanecarboxylate, (RS)-α-cyano-3-phenoxybenzyl (1R)-cis / trans-chrysanthemate, (S)-2-methyl-4-oxo-3-(2-propyl)-2-cyclopentenyl (1R)-cis / trans-chrysanthemate, and isomers thereof. Examples of organic antiviral, antibacterial, and antifungal agents include quaternary ammonium salts, pyridine compounds, halogenated phenols, and organic iodines.

[0032] When the resin portion is a thermally crosslinkable resin that crosslinks by heat, examples of the thermally crosslinkable resin include acrylic or polyurethane to which an epoxy-based crosslinking agent has been added, and from the viewpoint of washing durability at the end of consumption, those to which N-methylolacrylamide has been added are preferred.

[0033] The average diameter D of the resin portion can be 0.05 to 5.00 mm. From the viewpoint of suppressing fiber fragments from falling off the fiber base material, the average diameter D of the resin portion 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 portion can be set to 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 portion can be obtained by observing the resin portion in the resin-adhered fibrous substrate using a microscope and measuring the diameter of the resin portion. The diameters of 20 resin portions are measured while changing the measurement location so that the measurement locations are distributed approximately evenly throughout the resin-adhered fibrous substrate, and the average value of the 10 measurements, excluding the five largest and five smallest measurements, can be obtained as the average diameter D of the resin portion. If the shape of the resin portion is not a perfect circle, the area of ​​the resin portion can be measured using area calculation software built into the microscope, and the diameter of a perfect circle having that area can be obtained as the diameter of the resin portion.

[0037] The average number (points) P ​​per inch (25.4 mm) of the resin portion can be 5.0 to 50.0 pieces / 25.4 mm. From the viewpoint of being able to suppress fiber fragments from falling off from the fiber base material, 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, 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] The average number P of resin portions per 1 inch (25.4 mm) can be determined as follows. The measurement locations are changed so that the measurement locations of 25.4 mm in length and 25.4 mm in width are distributed approximately evenly throughout the resin-adhered fibrous substrate. The number of resin portions that are included in all or part of the measurement locations is measured using a striped magnifying glass for 20 measurement locations. The average of the 10 measurements, excluding the five largest and five smallest measurements, is calculated, and the square root of this average value can be obtained as the average number P of resin portions per 1 inch (25.4 mm). Here, if the size of the resin-adhered fibrous substrate is small and 20 measurement locations cannot be secured, or if the number of resin portions included in the 25.4 mm in length and 25.4 mm in width measurement locations is large and measurement is difficult, the size of the measurement locations may be adjusted appropriately and then proportionally adjusted to the area of ​​25.4 mm x 25.4 mm. Furthermore, if it is difficult to measure the resin portions at measurement locations with an appropriately adjusted size using a striped magnifying glass, the resin portions may be measured using a known microscope.

[0041] The lower the 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 portions. That is, the lower the value of D × P, the higher the appearance quality of the resin-adhered fibrous substrate. From the viewpoint of not making the user aware of the presence of the resin portions formed on the resin-adhered fibrous substrate, 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, or 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 other 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 portions. That is, the higher the value of D × P, the lower the appearance quality of the resin-adhered fibrous substrate. However, from the viewpoint of efficiently suppressing fiber fragment shedding, D × P can be greater 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, or 30.0 or more, and is preferably greater 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 portions attached to at least one surface of the resin-adhered fibrous substrate are arranged so that the average diameter D of the resin portions, the average number P of the resin portions, and the average number of twists T of the spun yarn satisfy the following formula (1): 8.6≦[D / {25.4 / (P−1)}]×P / T≦61.2 (1) Hereinafter, the numerical value represented by "[D / {25.4 / (P−1)}]×P / T" may be referred to as "parameter X."

[0044] The technical significance of parameter X will be explained. The numerical value indicated by "25.4 / (P-1)", which is a part of parameter X, is defined as "parameter Xa". Parameter Xa indicates the theoretical upper limit of the center-to-center distance between adjacent resin portions. The numerical value "D / (25.4 / (P-1))" obtained by dividing the average diameter D by parameter Xa is defined as "parameter Xb". Parameter Xb indicates the ratio of the average diameter of resin portions actually provided on the fiber substrate to the theoretical upper limit of the center-to-center distance between adjacent resin portions. In other words, parameter Xb indicates the force with which one resin portion provided on the fiber substrate restrains the spun yarn. It can be seen that the larger the value of parameter Xb, the greater the force with which one resin portion provided on the fiber substrate restrains the spun yarn.

[0045] The parameter Xb multiplied by the average number P per inch (25.4 mm) is given as "parameter Xc" (D / (25.4 / (P-1)) x P). That is, parameter Xc indicates the force with which all resin portions provided in the fiber base material bind the spun yarn. It can be seen that the larger the value of parameter Xc, the greater the force with which all resin portions provided in the fiber base material bind the spun yarn.

[0046] As the value of parameter Xc increases, the binding force of the resin portion on the spun yarn increases, which tends to make it easier to prevent microfibers from falling out. On the other hand, as the value of parameter Xc increases, the texture of the fiber base material tends to deteriorate. Furthermore, as the average twist number T of the spun yarn increases, the spun yarn's own ability to prevent microfibers from falling out increases. As a result, the effect of the resin portion in preventing microfibers from falling out tends to be relatively reduced. Parameter X represents the balance between these trends.

[0047] From the viewpoint of being able to suppress fiber fragments from falling off 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 feel, 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, 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 resin-coated fiber substrate described above can be applied to, for example, fabrics used in clothing, and fabrics used in daily life materials such as bed covers and sheets.

[0050] The shedding suppression method according to this embodiment is a method for suppressing shedding of synthetic fibers from a fiber substrate having a spun yarn formed using synthetic fibers. The shedding suppression method according to this embodiment includes a resin part formation step in which dot-shaped resin parts having an average diameter D of 0.05 to 5.00 mm and an average number P per inch in the range of 5.0 to 50.0 / 25.4 mm are formed 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 formation step of the shedding suppression method according to this embodiment forms the average diameter D and 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 value of "[D / {25.4 / (P-1)}]×P / T" in the above formula (3) is the same as the above "parameter X."

[0051] The drop-off prevention method according to this embodiment can increase the drop-off improvement rate, which will be described in detail later. The drop-off prevention method according to this embodiment can achieve a drop-off improvement rate of 10% or more. The drop-off prevention method according to this embodiment can impart a good texture. For example, the drop-off prevention method according to this embodiment can be given a rating of "B" or higher in the evaluation method described in the examples below. Furthermore, the drop-off prevention method according to this embodiment can impart a good appearance quality. For example, the drop-off prevention method according to this embodiment can be given a rating of "B" or higher in the evaluation method described in the examples below.

[0052] According to one aspect of the shedding prevention method of the present embodiment, the average diameter D, the average number P, and the average number of twists 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 shedding prevention method of the present embodiment, a shedding improvement rate of 30% or more can be achieved. According to the shedding prevention method of the present embodiment, a good texture can be imparted. For example, according to the shedding prevention method of the present embodiment, a rating of "A" or higher can be given in the evaluation method described in the examples below.

[0053] According to one aspect of the shedding suppression method of this embodiment, the average diameter D, average number P, and 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 shedding suppression method of this embodiment, a shedding improvement rate of 35% or more can be achieved. The resin-adhered fibrous substrate of this embodiment can provide a good texture. For example, the shedding suppression method of this embodiment can be given a rating of "A" or higher in the evaluation method described in the examples below.

[0054] Hereinafter, one aspect of the present invention will be described in more detail with reference to examples and comparative examples, but one aspect of the present invention is not limited to the following examples.

[0055] <Preparation of Resin-Coated Fabric for Evaluation> (Example 1) A polyester staple fiber was spun in a known spinning machine while adjusting the spindle and torque so as to obtain a spun yarn having an average fineness of 197 dtex and an average twist of 0.47 turns / mm. In Example 1, this spun yarn was woven in a plain weave and dyed to obtain a woven fabric for evaluation 1 having a weft density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0056] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 1 to form a resin-attached fabric 1 for evaluation. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 1 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.50 mm, the number P of resin portions per 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) Polyester staple fibers were spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining spun yarn 2 having an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Example 2, this spun yarn 2 was used as the warp and weft to form a plain weave, which was then dyed and finished to obtain evaluation fabric 2 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0058] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 2 to form a resin-attached evaluation fabric 2. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 2 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.20 mm, the number P of resin portions per 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 in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.94 turns / mm, thereby obtaining a spun yarn 3 having 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 form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 3 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0060] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 3 to form a resin-attached evaluation fabric 3. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 3 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.50 mm, the number P of resin portions per 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 in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining spun yarn 4 having 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 form a plain weave, which was then dyed and finished to obtain evaluation fabric 4 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

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

[0063] (Example 5) Polyester staple fibers were spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.24 turns / mm, thereby obtaining a spun yarn 5 having an average fineness of 197 dtex and a twist of 0.24 turns / mm. In Example 5, this spun yarn 5 was used as the warp and weft to form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 5 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0064] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 5 to form a resin-attached evaluation fabric 5. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 5 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 2.00 mm, the number P of resin portions per 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.

[0065] (Example 6) A polyester staple fiber was spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining a spun yarn 6 having an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Example 6, this spun yarn 6 was used as the warp and weft to weave in a plain weave, and dyed and finished to obtain a woven fabric for evaluation 6 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0066] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 6 to form a resin-attached evaluation fabric 6. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 6 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 2.00 mm, the number P of resin portions per 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 in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining spun yarn 7 having an average fineness of 197 dtex and a twist of 0.47 turns / mm. In Example 7, this spun yarn 7 was used as the warp and weft to form a plain weave, which was then dyed and finished to obtain evaluation fabric 7 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0068] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 7 to form a resin-attached evaluation fabric 7. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 7 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.10 mm, the number P of resin portions per 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 in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining a spun yarn 8 having an average twist of 197 dtex and a twist of 0.47 turns / mm. In Example 8, this spun yarn 8 was used as the warp and weft to weave in a plain weave, and dyed and finished to obtain a woven fabric for evaluation 8 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0070] Resin portions were arranged in a dot pattern on one surface of the evaluation fabric 8 to form a resin-attached evaluation fabric 8. Specifically, dot-shaped paste that would become the resin portions was transferred to one surface of the evaluation fabric 8 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 1.40 mm, the number P of resin portions per 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) Polyester staple fibers were spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining a spun yarn 11 having 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 yarn to form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 11 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0072] Resin portions were arranged in a dot pattern on one side of the evaluation fabric 11 to form a resin-attached evaluation fabric 11. Specifically, dot-shaped paste that would become the resin portions was transferred to one side of the evaluation fabric 11 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.10 mm, the number P of resin portions per 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) A polyester staple fiber was spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining a spun yarn 12 having 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 form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 12 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0074] Resin portions were arranged in a dot pattern on one side of the evaluation fabric 12 to form a resin-attached evaluation fabric 12. Specifically, dot-shaped paste that would become the resin portions was transferred to one side of the evaluation fabric 12 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.60 mm, the number P of resin portions per 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) Polyester staple fibers were spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.94 turns / mm, thereby obtaining a spun yarn 13 having an average fineness of 197 dtex and a twist of 0.94 turns / mm. In Comparative Example 3, this spun yarn 13 was used as the warp and weft to form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 13 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0076] Resin portions were arranged in a dot pattern on one side of the evaluation fabric 13 to form a resin-attached evaluation fabric 13. Specifically, dot-shaped paste that would become the resin portions was transferred to one side of the evaluation fabric 13 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.10 mm, the number P of resin portions per 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) A polyester staple fiber was spun in a known spinning machine while adjusting the spindle and torque so as to obtain an average fineness of 197 dtex and an average twist of 0.47 turns / mm, thereby obtaining a spun yarn 14 having 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 to form a plain weave, which was then dyed and finished to obtain a woven fabric for evaluation 14 having a warp density of 85 threads / 25.4 mm and a weft density of 70 threads / 25.4 mm.

[0078] Resin portions were arranged in a dot pattern on one side of the evaluation fabric 14 to form a resin-attached evaluation fabric 14. Specifically, dot-shaped paste that would become the resin portions was transferred to one side of the evaluation fabric 14 using a rotary screen with an adjusted pitch and opening diameter. The resin portions were formed using a resin primarily made from NIT-094 (acrylic emulsion) manufactured by Nissin Chemical Industry Co., Ltd. The average diameter D of the resin portions was 0.60 mm, the number P of resin portions per 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] The average diameter D, the number P of resin portions, D×P, and the average number of twists T of Examples 1 to 8 and Comparative Examples 1 to 4 are summarized in Table 1 below.

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

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

[0082] <Method of Calculating the Improvement Rate of Fiber Fragment Shedding> Evaluation fabrics (evaluation fabrics 1 to 8, 11 to 14) and evaluation resin-attached fabrics (evaluation fabrics 1 to 8, 11 to 14) in which dot-shaped resin portions were provided on the evaluation fabrics were prepared. For example, evaluation resin-attached fabric 1 is evaluation fabric 1 in which dot-shaped resin portions were provided. In other words, evaluation fabric 1 is obtained by removing the dot-shaped resin portions from evaluation resin-attached fabric 1. Next, four pieces measuring 17 cm long x 10 cm wide were cut out from each of these evaluation resin-attached fabrics and evaluation fabrics, and the edges of these were sewn in by 1.25 cm to create four samples each with a final finished size of 12 cm long x 5 cm wide.

[0083] Next, one of the resin-attached fabric samples for evaluation and 25 stainless steel balls were placed in a washing machine pot for color fastness testing, and 150 ml of purified water was poured in. No detergent was added to the pot. The pot was then covered, the bath temperature was adjusted to 40°C, and 10 washing cycles were performed, each cycle lasting 30 minutes. After the 10 washing cycles, the waste liquid was suction filtered and the amount of fiber fragments that had fallen off was measured. The remaining three resin-attached fabric samples for evaluation were also measured for the amount of fiber fragments that had fallen off using the same method. The average amount of fiber fragments that had fallen off from the four resin-attached fabric samples for evaluation was used to calculate the improvement rate in fiber fragment shedding, as described below, and was designated the "amount of fiber fragments that had fallen off from the resin-attached fabric for evaluation."

[0084] In addition, the amount of fiber fragments that had fallen off was measured for each of the four samples of the evaluation fabric using the above method, and the average amount of fiber fragments that had fallen off for the four samples of the evaluation fabric was used as the ``amount of fiber fragments that had fallen off in the evaluation fabric'' to be used in calculating the fiber fragment fall-off improvement rate described below.

[0085] The fiber fragment shedding improvement rate is calculated based on the amount of fiber fragments that have fallen off in the evaluation fabric and the amount of fiber fragments that have fallen off in the evaluation fabric, according to the following formula (5): Shedding improvement rate = (amount of fiber fragments that have fallen off in the evaluation fabric - amount of fiber fragments that have fallen off in the resin-attached evaluation fabric) / amount of fiber fragments that have fallen off in the evaluation fabric (5).

[0086] <Evaluation of the feel of the resin-coated fabric> The feel was evaluated by a sensory test conducted by five skilled experts. The evaluation criteria were A, B, or C. The evaluation criteria were as follows: Criterion A: When five out of five people compare the above-mentioned evaluation resin-attached woven fabrics 1 to 8, 11 to 14 with the corresponding evaluation fabrics 1 to 8, 11 to 14, they judge that there is no difference in texture. Criterion B: When four or more people compare the above-mentioned evaluation resin-attached woven fabrics 1 to 8, 11 to 14 with the corresponding evaluation fabrics 1 to 8, 11 to 14, they judge that there is no difference in texture, or that there is a noticeable difference in texture but it is acceptable (excluding cases that fall under Criterion A). Criterion C: When two or more people compare the above-mentioned evaluation resin-attached woven fabrics 1 to 8, 11 to 14 with the corresponding evaluation fabrics 1 to 8, 11 to 14, they judge that there is a significant difference in texture and that the texture is not acceptable for clothing.

[0087] <Evaluation of appearance quality of resin-attached fabric> The appearance quality was evaluated based on whether five evaluators with normal eyesight could see the dot-shaped resin parts formed on the resin-attached fabric for evaluation. Criterion A: When four or more of the five judged that the dot-shaped resin parts were easily visible, i.e., when the appearance quality was judged to be excellent. Criterion B: When two or more of the five judged that the dot-shaped resin parts were difficult to see and that checking at close range or using a magnifying glass or the like was necessary, i.e., when the appearance quality was judged to be poor.

[0088] Although one embodiment has been described above, one aspect of the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention.

[0089] In the above embodiment, the resin portions are formed on only one side of the resin-adhered fibrous substrate, but they may be formed on both sides of the resin-adhered fibrous substrate. In this case, the average number P of resin portions is calculated based on the sum of the number of resin portions formed on the front side of the fibrous substrate and the number of resin portions formed on the back side of the fibrous substrate.

Claims

1. A resin-adhered fiber substrate comprising: 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, wherein 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 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 portions / 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) 2. The resin-attached fiber substrate according to claim 1, wherein the average diameter D and the average number P of the resin portions satisfy the following formula (2): 15.7≦[D / {25.4 / (P−1)}]×P / T≦38.2 (2) 3. A method for suppressing shedding of synthetic fibers from a fiber substrate having a spun yarn formed containing synthetic fibers, the method comprising: forming dot-shaped resin parts having an average diameter D 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 the fiber substrate having the spun yarn with an average twist number T in the range of 0.10 to 3.00 turns / mm, the resin part forming step forming the resin parts so as to satisfy the following formula (3): 8.6≦[D / {25.4 / (P-1)}]×P / T≦61.2...(3) 4. The method for preventing falling off as described in claim 3, wherein the resin portion forming step forms the average diameter D and the average number P of the resin portions so as to satisfy the following formula (3). 15.7≦[D / {25.4 / (P-1)}]×P / T≦38.2...(4)

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