Pile fabric and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-12286732-B2
Application number	US-202217720637-A
Country	US
Kind code	B2
Filing date	Apr 14, 2022
Priority date	Dec 25, 2019
Publication date	Apr 29, 2025
Grant date	Apr 29, 2025

Abstract

A pile fabric includes a long pile portion and a short pile portion. An average pile length of the long pile portion differs from an average pile length of the short pile portion by 2 mm or more. The long pile portion contains crimped polyester-based fibers in an amount of 60% by weight or more. The short pile portion contains crimped polyester-based fibers in an amount of 60% by weight or more. A crimp removal temperature of the polyester-based fibers of the long pile portion is lower than a crimp removal temperature of the polyester-based fibers of the short pile portion. The crimp removal temperature of the polyester-based fibers of the short pile portion is 90° C. or more and 120° C. or less. Each of the crimp removal temperatures indicates a minimum temperature that satisfies a specific relationship. A method for manufacturing the pile fabric is also provided.

First claim

What is claimed:

1. A pile knitted fabric, comprising:
a knitted pile portion that comprises a long pile portion and a short pile portion, wherein
an average pile length of the long pile portion differs from an average pile length of the short pile portion by 2 mm or more,
the long pile portion comprises crimped polyester-based fibers in an amount of 60% by weight or more,
the short pile portion comprises crimped polyester-based fibers in an amount of 60% by weight or more,
a crimp removal temperature of the crimped polyester-based fibers of the long pile portion is lower than a crimp removal temperature of the crimped polyester-based fibers of the short pile portion,
the crimp removal temperature of the crimped polyester-based fibers of the short pile portion is 90° C. or more and 120° C. or less, and
each of the crimp removal temperatures indicates a minimum temperature that satisfies the following numerical formula (1):
( A−B )/ A× 100<3(%)  (1)

where, in the formula (1),
A represents a length of a fiber bundle of the crimped polyester-based fibers under a load of 4 mg/dtex after the fiber bundle is subjected to dry heat treatment at a predetermined temperature for 60 seconds under a load of 4 mg/dtex, and
B represents a length of the fiber bundle of the crimped polyester-based fibers under no load after the fiber bundle is subjected to the dry heat treatment at the predetermined temperature for 60 seconds under a load of 4 mg/dtex.

2. The pile knitted fabric according to claim 1 , wherein the crimp removal temperature of the crimped polyester-based fibers of the long pile portion is 90° C. or less.

3. The pile knitted fabric according to claim 1 , wherein the short pile portion has a single fiber fineness of 1 dtex or more and 10 dtex or less.

4. The pile knitted fabric according to claim 1 , wherein the long pile portion has a single fiber fineness of 10 dtex or more and 40 dtex or less.

5. The pile knitted fabric according to claim 1 , wherein the pile knitted fabric comprises:
the short pile portion in an amount of 50% by weight or more and 95% by weight or less of a total weight of the knitted pile portion; and
the long pile portion in an amount of 5% by weight or more and 50% by weight or less of the total weight of the knitted pile portion.

6. A method for manufacturing the pile knitted fabric according to claim 1 , comprising polishing at a temperature of 90° C. or more and 160° C. or less.

7. The method according to claim 6 , wherein the crimp removal temperature of the crimped polyester-based fibers of the long pile portion is 90° C. or less.

8. The method according to claim 6 , wherein the short pile portion has a single fiber fineness of 1 dtex or more and 10 dtex or less.

9. The method according to claim 6 , wherein the long pile portion has a single fiber fineness of 10 dtex or more and 40 dtex or less.

10. The method according to claim 6 , wherein the pile knitted fabric comprises:
the short pile portion in an amount of 50% by weight or more and 95% by weight or less of a total weight of the knitted pile portion; and
the long pile portion in an amount of 5% by weight or more and 50% by weight or less of the total weight of the knitted pile portion.

11. The pile knitted fabric according to claim 1 , wherein the long pile portion comprises:
the crimped polyester-based fibers in an amount of 60% by weight or more and 100% by weight or less; and
a modacrylic fiber in an amount of 40% by weight or less.

12. The pile knitted fabric according to claim 1 , wherein the crimped polyester-based fibers of the long pile portion and the short pile portion each comprise a cross-sectional shape comprising at least one selected from the group consisting of Y shapes, cocoon shapes, four skewered-dumpling shapes, and five skewered-dumpling shapes.

13. The method according to claim 6 , wherein the long pile portion comprises:
the crimped polyester-based fibers in an amount of 60% by weight or more and 100% by weight or less; and
a modacrylic fiber in an amount of 40% by weight or less.

14. The method according to claim 6 , wherein the crimped polyester-based fibers of the long pile portion and the short pile portion each comprise a cross-sectional shape comprising at least one selected from the group consisting of Y shapes, cocoon shapes, four skewered-dumpling shapes, and five skewered-dumpling shapes.

15. The pile knitted fabric according to claim 1 , wherein the crimp removal temperature of the crimped polyester-based fibers of the long pile portion differs from the crimp removal temperature of the crimped polyester-based fibers of the short pile portion by 10° C. or more.

16. The pile knitted fabric according to claim 1 , wherein the crimped polyester-based fibers of the short pile portion comprise a cross-sectional shape comprising at least one selected from the group consisting of Y shapes and cocoon shapes.

Assignees

• Kaneka Corp

Inventors

• Hirai Yusuke
• TAOKA Nobutaka
• Shinbayashi Hiroyuki
• Tokumoto Hiroyuki

Classifications

• D10B2501/044

  Fur garments; Garments of fur substitutes · CPC title

• D04B1/025 Primary

  incorporating loose fibres, e.g. high-pile fabrics or artificial fur · CPC title

• D10B2331/04

  polyesters, e.g. polyethylene terephthalate [PET] · CPC title

• D10B2321/101

  modacrylic · CPC title

• D06N3/0077

  Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish · CPC title