Method for manufacturing pile fabric

Patent metadata

Field	Value
Publication number	US-9702061-B2
Application number	US-201314430072-A
Country	US
Kind code	B2
Filing date	Sep 18, 2013
Priority date	Sep 24, 2012
Publication date	Jul 11, 2017
Grant date	Jul 11, 2017

Abstract

The present invention relates to a pile fabric including an acrylic synthetic fiber at a napped portion, the acrylic synthetic fiber is obtained by spinning a spinning solution including 90 to 99 parts by weight of a polymer A and 1 to 10 parts by weight of a polymer B. The polymer A is a polymer obtained by polymerizing a composition A including 40 to 97 wt % of acrylonitrile, 0 to 5 wt % of a sulfonic acid-containing monomer and 3 to 60 wt % of another copolymerizable monomer. The polymer B is obtained by polymerizing a composition B including 0 to 70 wt % of acrylonitrile, 20 to 90 wt % of acrylic ester and 10 to 40 wt % of a sulfonic acid-containing monomer, and the polymer B is a polymer to be dissolved in a mixed solvent composed of water and at least one organic solvent selected from the group consisting of N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide and acetone. The acrylic synthetic fiber forming the napped portion is dyed or discharge-printed at least partially, and the dyed or discharge-printed acrylic synthetic fiber has an apparent specific gravity in a range of 0.8 to 1.1.

First claim

The invention claimed is:

1. A method for manufacturing a pile fabric comprising an acrylic synthetic fiber at a napped portion of a pile fabric, wherein the acrylic synthetic fiber is a fiber obtained by spinning a spinning solution comprising a polymer A and a polymer B; the polymer A is 90 to 99 parts by weight and the polymer B is 1 to 10 parts by weight when the total weight of the polymer A and the polymer B in the spinning solution is 100 parts by weight; the polymer A is a polymer obtained by polymerizing a composition A that is a composition comprising 40 to 97 wt % of acrylonitrile, 0 to 5 wt % of sulfonic acid-containing monomer and 3 to 60 wt % of another copolymerizable monomer when the total weight of the composition A is 100 wt %; the polymer B is a polymer that is obtained by polymerizing a composition B and that is dissolved in a mixed solvent comprising water and at least one organic solvent selected from the group consisting of N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide and acetone; and the composition B is a composition comprising 0 to 70 wt % of acrylonitrile, 20 to 90 wt % of acrylic ester and 10 to 40 wt % of sulfonic acid-containing monomer when the total weight of the composition B is 100 wt %,
the method comprising:
dyeing at least partially the acrylic synthetic fiber before forming the napped portion of the pile fabric or after forming the napped portion of the pile fabric to make a dyed acrylic synthetic fiber;
discharge-printing the pile fabric comprising the dyed acrylic synthetic fiber at the napped portion to make a discharge-printed acrylic synthetic fiber at the napped portion of the pile fabric; and
separately from the discharge-printing, adding water to the dyed acrylic synthetic fiber or the discharge-printed acrylic synthetic fiber at the napped portion of the pile fabric in an amount of more than 43 parts by weight with respect to 100 parts by weight of the dyed acrylic synthetic fiber or the discharge-printed acrylic synthetic fiber at the napped portion of the pile fabric, and carrying out a wet-heat treatment at a temperature higher than 80° C., wherein, after the adding water step, the dyed acrylic synthetic fiber or the discharge-printed acrylic synthetic fiber at the napped portion of the pile fabric has an apparent specific gravity in a range of 0.8 to 1.1.

2. The method for manufacturing the pile fabric according to claim 1 , wherein the polymer B is a polymer that is dissolved at a concentration of 1 wt % or more in a mixed solvent composed of 20 wt% of distilled water and 80 wt % of at least one organic solvent selected from the group consisting of N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide and acetone when the total weight of the mixed solvent is 100 wt % at 40° C.

3. The method for manufacturing the pile fabric according to claim 1 , wherein the discharge-printing treatment comprises a discharging step and/or a printing step.

4. The method for manufacturing the pile fabric according to claim 1 , wherein the wet-heat treatment is carried out at a temperature of 85° C. or higher and lower than 120° C.

5. The method for manufacturing the pile fabric according to claim 1 , wherein the water is added in an amount of 60 parts by weight or more and 200 parts by weight or less with respect to 100 parts by weight of the acrylic synthetic fiber forming the napped portion of the pile fabric.

6. The method for manufacturing the pile fabric according to claim 1 , wherein the wet-heat treatment is carried out for 30 minutes or more and 2 hours or less.

7. The method for manufacturing the pile fabric according to claim 2 , wherein the discharge-printing treatment comprises a discharging step and/or a printing step.

8. The method for manufacturing the pile fabric according to claim 2 , wherein the wet-heat treatment is carried out at a temperature of 85° C. or higher and lower than 120° C.

9. The method for manufacturing the pile fabric according to claim 3 , wherein the wet-heat treatment is carried out at a temperature of 85° C. or higher and lower than 120° C.

10. The method for manufacturing the pile fabric according to claim 2 , wherein the water is added in an amount of 60 parts by weight or more and 200 parts by weight or less with respect to 100 parts by weight of the acrylic synthetic fiber forming the napped portion of the pile fabric.

11. The method for manufacturing the pile fabric according to claim 3 , wherein the water is added in an amount of 60 parts by weight or more and 200 parts by weight or less with respect to 100 parts by weight of the acrylic synthetic fiber forming the napped portion of the pile fabric.

12. The method for manufacturing the pile fabric according to claim 4 , wherein the water is added in an amount of 60 parts by weight or more and 200 parts by weight or less with respect to 100 parts by weight of the acrylic synthetic fiber forming the napped portion of the pile fabric.

13. The method for manufacturing the pile fabric according to claim 2 , wherein the wet-heat treatment is carried out for 30 minutes or more and 2 hours or less.

14. The method for manufacturing the pile fabric according to claim 3 , wherein the wet-heat treatment is carried out for 30 minutes or more and 2 hours or less.

15. The method for manufacturing the pile fabric according to claim 4 , wherein the wet-heat treatment is carried out for 30 minutes or more and 2 hours or less.

16. The method for manufacturing the pile fabric according to claim 5 , wherein the wet-heat treatment is carried out for 30 minutes or more and 2 hours or less.

17. The method for manufacturing the pile fabric according to claim 1 , wherein the composition A comprises 40 to 70 wt % of acrylonitrile, 0 to 5 wt % of sulfonic acid-containing monomer and 30 to 60 wt % of another copolymerizable monomer when the total weight of the composition A is 100 wt %.

18. The method for manufacturing the pile fabric according to claim 1 , wherein the other copolymerizable monomer is a halogen-containing monomer.

19. The method according to claim 1 , wherein the discharge-printing treatment comprises a discharging step, the discharging step being carried out by applying a discharge paste including a discharging agent on the surface of the pile fabric and steaming the discharge past on the surface of the pile fabric.

20. The method according to claim 19 , wherein the wet-heat treatment is carried out by water vapor.

21. The method according to claim 1 , wherein the wet-heat treatment is carried out by water vapor.

22. A method for manufacturing a pile fabric comprising an acrylic synthetic fiber at a napped portion of a pile fabric, wherein the acrylic synthetic fiber is a fiber obtained by spinning a spinning solution comprising a polymer A and a polymer B; the polymer A is 90 to 99 parts by weight and the polymer B is 1 to 10 parts by weight when the total weight of the polymer A and the polymer B in the spinning solution is 100 parts by weight; the polymer A is a polymer obtained by polymerizing a composition A that is a composition comprising 40 to 97 wt % of acrylonitrile, 0 to 5 wt % of sulfonic acid-containing monomer and 3 to 60 wt % of another copolymerizable monomer when the total weight of the composition A is 100 wt %; the polymer B is a polymer that is obtained by polymerizing a composition B and that is dissolved in a mixed solvent comprising water and at least one organic solvent selected from the group consisting of N,N-dimethylformami

Assignees

• Kaneka Corp

Inventors

• Anahara Masaru
• Nishida Sohei

Classifications

• D01F6/52

  of polymers of unsaturated carboxylic acids or unsaturated esters · CPC title

• D03D15/00

  Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used · CPC title

• D06P5/2077

  after dyeing · CPC title

• D01F1/06 Primary

  Dyes · CPC title

• D01F6/38 Primary

  comprising unsaturated nitriles as the major constituent · CPC title