The present invention relates to anti-pilling fabrics and their preparation containing short fibers of thermoplastic synthetic fibers. More particularly, the present invention is the long fiber yarn of thermoplastic synthetic fibers and / or to pilling woven or knitted fabric and its production method including a spun yarn comprising short fibers.
BACKGROUND
[0002]
　Natural fibers are short fibers (staple) which are cut in a short length except silk. For example, cotton about 20 ~ 35 mm in length, a thickness of about 20 [mu] m, wool (merino) is the length of about 7.5 ~ 120 mm, thickness 13 ~ 28 .mu.m. Therefore, the natural fibers, loosened staple fibers are spun yarn by spinning for as Kushikezuru arranged fibers and the yarn bundles are twisted (hereinafter, also referred to as a spun yarn.). The spun yarn, there is fluff in places, have bulkiness, flexible, has a characteristic that there is a warmth.
　On the other hand, synthetic fibers are typically made as filaments through a spinning, for example, many of the fibers, such as polyester or polyamide is made from melt-spun acrylic fibers are made by wet spinning. Also, regenerated cellulose fibers such as rayon or cupra, even semi-synthetic fibers such as acetate fibers, made as filaments. Synthetic fibers are also used as the short fibers by cutting those made as filaments.
[0003]
　Synthetic fibers, although with cotton and linen, silk, characterized in that the strong generally lightly compared to the natural fibers of wool, etc. (hard to cut strongly), natural fibers are often those with the unique texture that is soft and, It is preferably used as mainly of clothing raw materials. The soft and texture possessed by natural fibers in order to achieve synthetic fibers is a woven or knitted fabric in the spun yarn of synthetic fibers than may be woven, the woven or knitted fabric made from spun yarns of synthetic fibers, is pilling it is known that tends to occur. The pilling, fabric surface is friction during washing and wearing, fuzz fabric surface, fluff entangled, means that the can small pill (pill), in particular, include synthetic fibers such as polyester or polyamide in the fiber and has been, the pill for which the fiber is less likely to cut strongly is likely to occur. While pill generated is can I fall off, since the extending not completely when these synthetic fibers is pulled once, hardly fall off the pills occurs, promoting the degradation of the woven or knitted fabric with disfiguring. Therefore, the use of the product, such as repeating the clothing and laundry, measures to suppress the occurrence of pilling in the case of producing a woven or knitted fabric that uses the spun yarn of the synthetic fiber (i.e., anti-pilling measures) is indispensable .
[0004]
　Conventionally, for example, in the preparation process before dyeing, in particular, in the spinning cloth, such as cotton, woven fabrics, often come out the fluff in the knitted fabric, the surface of the dyeing and fluff often become blurred In addition, hair it will cause balls occurs, to remove fuzz, burning off and fluff carbonized by a gas burner or electric heater performs so-called "singeing" have been made to smooth the fiber surface. In the previous dyeing, but singeing is performed after Oage, it has also been made to perform the yarn.
[0005]
　On the other hand, in the textile products, as described below, have been made to make to actively fluff and brushed the woven or knitted fabric.
　In the cotton products such as jeans, and cover the cloth surface with a fluff, soft, become a rich feeling, colors and patterns or blurred whitish, changes to a calm feeling, in order to begin to drift even luxury, thinned by washed-out However the fluff, have been made to the worn was feeling.
　In the wool, after the organization raised, indicating the stiff and greige, strike, out the fluff and the Chijimi絨to be felted by, for example, rub, export the fiber of the fabric surface in order to further put out the fluff, cut, fluff the have brushed is performed to produce, in clothings roll having a metal needle, and clothing brushed issues fluff scratching the fabric face, and rubbing the cloth table real thorn thistle, milder than clothing brushed a brushed effect of feeling can be obtained, the so-called thistle brushed is known.
　Natural cashmere and angora tone smooth the soft touch, moisture retention, in order to obtain a highly sensitive fabrics with a touch, the short fiber spun yarn Tsukai of woven or knitted synthetic fibers such as polyester or acrylic, clothing raising processing to have been made to make a very long fluff called woolen to high density.
[0006]
　Also, performed on the underlying, it is polished by sandpaper called emery paper, emery processing (chamois processing) to make a short nap finer are also known. Eye sandpaper differ, even sanding process known as raising processing to polyester fabric, which performs brushed sandpaper, degree of raising the roller of different sandpaper, overlapping plural, vertically, It is rotated at a low speed, and friction by passing the fabric between them, has also been possible to thin brushed.
[0007]
　In particular, the present invention was performed wool or brushed, shaved processing mow fluff fabric face performed (shearing), and the like reap fluff length cutting aligned or messy, clearly represent the weave and color patterns or, it has been made to arrange the appearance.
[0008]
　Patent Document 1 below, a fineness of 1.0 to consist knitted fabric knitted by the blended yarn with 2.5 denier polyester staple fibers and cotton fibers, the component ratio is 75 to cotton fibers in the blended yarn 90 %, twist coefficient of the blended yarn is 3.0 to 4.5, and shirts for the knitted fabric, characterized in that it is singeing after the organization has been disclosed. In cited document 1, the component ratio is less than 75% of the cotton fibers (i.e., polyester staple component ratio of the fibers is more than 25%), the texture becomes hard to melt the polyester staple fibers during singeing after knitting together, it is described that easily soiled. In other words, when adopting the singeing adopted as pilling measure natural fibers as pilling measures polyester synthetic fiber, rather than fluff cause pilling as natural fibers from falling off carbonized, the molten ball is generated in the fluff of the hair of polyester, this has resulted in a deterioration of texture such as roughness of fabric.
[0009]
　Patent Document 2 below, when singeing synthetic fibers, in order to obtain a soft texture, such as cashmere, polyester fibers, polyamide fibers, napped brushed fabrics having napped made of synthetic fibers such as acrylic fibers after the tip was singeing process brought form a molten ball of synthetic fibers, by the upstanding bristles tip, treated with solvent or hydrolyzing agent of the synthetic fibers of a predetermined viscosity, heat treatment, upstanding hair tip part is narrowed to have a method of manufacturing the animal hair Chofu land has been disclosed. This molten ball forming portion becomes amorphous unoriented state, solvent, dissolution rate when treated with a hydrolyzing agent, the tip very sharp along with the hydrolysis rate can be significantly shortened significantly larger becomes the processing time is based on can be narrowed. However, in the method of treating with a solvent or hydrolyzing agent of synthetic fibers, because the lowered is material strength, not only applies to limited applications of such women's clothing today.
[0010]
　Patent Document 3 below, a synthetic fiber-containing yarn with a reduced fluff per sectional number of fibers in the warp and / or weft, singeing and / or caustic is not subjected by the specific spinning method denim , a fabric such as Dangari, washing (JIS L0217 103 method) after 10 times, and pilling fabric pilling resistance by JIS L1076 a method (ICI type tester 5 hours) is a tertiary or higher is disclosed there. Patent Document 3, the synthesis the use of fiber spun yarn, but singeing process for preventing pilling synthetic fibers are required, the resulting synthetic fiber molten ball hot caustic and mercerized treatment or shearing will need a costly process of removing or the like, and also, texture, can exacerbate a robust level, and the like, also, than singeing only stimulate the molten ball is skin present on the fabric surface, repeating the washing and the wearer in abraded molten ball is a fabric surface, easily induced fuzz, fabric surface quality, it exacerbates wearing feeling, also, like in the denim and Dangari, high pressure long strong acids, chemical treatment process such as alkali since required, we like the product are not widespread to use synthetic fiber-containing yarn is described.
[0011]
　The following Patent Document 4, a single fiber fineness of 0.01 to 10 denier, the span woven or knitted fabric comprising a polyester monofilament having a single fiber strength 2.5 g / denier or more and clothing raising processing, thereafter woven or knitted fabric in the surface of the flexible rough surface material having a surface of the polishing film, the beating-abraded treated on the support roller surface, the surface fluff to an average fluff length of at least 1.1mm than 50mm or less, and an average fluff density There method of manufacturing a polyester spun woven or knitted fabric is disclosed to finish so that more than 200 present / cm. Further, cutting in such tapping-rubbing treatment, with reaps while pulling strongly rough surface material having flexibility with a surface of the clothing brushed processed napped surface of the long coarse fluff the abrasive film, the mass of loops and fibers , removed, it is described that generates a new slightly shorter dense fluff. Patent Document 4, the buffing by conventional emery roll JIS While pilling resistance was 1-2 grade according to L1076, in the processing method using the polishing film it is also described that was 5,4-5 grade. Patent Document 4, improvement in polyester staple fiber yarn having a high property, but commercialization is proceeding normally short fuzz worsted woven because it takes a short fiber spun fabrics made of woolen yarn is long fluff knitted against undergo friction by fluff washing and wearing of the fabric surface, quickly pill is generated called pilling, quality of the fabric, the appearance is greatly impaired, be a problem, it is short fiber fluff fabric surface by being rubbed, fluff present on the surface or in fluff is drawn from within the fabric, the entanglement fluff together, the fluff entangled strength dropping hardly fibers, synthetic fibers such as elongation is large polyester be particularly problematic, as a countermeasure against such pilling and minor disadvantage generation called Momoke pilling, (1) a method of reducing reformed fiber strength, the elongation, Method of increasing tissue binding of 2) fabrics, (3) a method of surface fluff is embrittled, (4) a method of the singeing process, (5) a method of resin treatment is known, in any case also it has advantages and disadvantages, to obtain a polyester spun woven or knitted fabric having excellent pilling resistance of fluffy woolen adjusted by software has been described to be very difficult.
[0012]
　Patent Document 4, in particular, singeing process is a method that is applied with a short fuzz combing textile fabric is a method of surface fuzz fabric to singeing processed by a gas burner when finishing dyeing of the fabric, It does not apply to fluff long woolen, although if applied also anti-pill effect is observed in its own way, since the fluff molten ball (melt ball) remains on the surface, the texture is rough, texture due to the heat treatment that there is a cure, it is described that there are problems such as lack of thermal insulation. Thus, the technique disclosed in Patent Document 4, the fluff woolen woven or knitted with synthetic fiber yarn, instead of pilling measures of the prior art, the short dense fluff with a particular polishing method it is obtained by applying the anti-pilling measures to be generated. In the cited document 4, conventional buffing, sanding process are the grinding by Emery roll or emery belt, because otherwise pilling effects not obtained, instead of this, the metal plate is laminated to the tip thick sharp feathered which depleted, and the flexible rough surface material having a surface of the polishing film is rotated on the support rollers surface, the span woven or knitted fabric beating and rubbing treatment is finished. Point of such specific polishing process, while pulling strongly long coarse nap of clothing brushed sharp rough material shear, a mass of loops and fibers cut, removed at the same time, new slightly shorter dense fluff by generating and to create surfaces, that is, by removing the "play hair" pole surface, "strong hair" create only been described that impart anti-pilling and enhanced abrasion resistance ing.
[0013]
　The following Patent Document 5, while the fabric is woven using a gluing warp is run at a predetermined speed, by contacting the said textile in a ceramic roller composed of an inorganic powder of grain size of # 100-800, thistle brushed rather than withdrawing the fibers from the inside as or clothing brushed, only it can be texture soft Momokawajo fibrillated surface, and improves the pilling characteristics, rope wrinkle, rubbing shaped plaque and it is possible to brushed against the fabric of thin cloth, such as Boyle no occurrence of tissue disorder and the like, yet the production method of the brushed fabric never tear strength of the fabric is reduced is disclosed by raising . Patent Document 5, as compared with the polishing with the conventional emery paper (# 200), the polishing by ceramic roller made of an inorganic powder of grain size of # 100-800, improves the texture and pilling resistance, also, fiber for only the fibrillated generate fine fluff surface, it has been described that does not require a post-treatment by chemical means using physical means or chemicals singeing and shaved like after raising.
[0014]
　Patent Document 6 below, the monomer constituting the synthetic fibers, to impart anti-pilling 及高 contractility (bulkiness) by modifying synthetic fibers obtained by copolymerizing by blending a monomer for improving the pilling resistance There has been disclosed. However, the available fiber material is limited to a polyester, lost properties and texture with synthetic fiber inherently more by modification of fibers, there is a problem accompanied by a decrease or increase in cost of the fiber strength.
[0015]
　As described above, as the pilling measures the spun yarn woven or knitted material using synthetic fibers, although with references 1 and 2, singeing, in references 3-6, one should use the singeing rather it has been taught not. Incidentally, as described above, since the cited reference 3, although the molten ball by singeing synthetic fibers is described, such as whether it is removable with shearing, shearing is originally a method reaps brushed fibers, it is practically difficult to apply to other cases of polishing as well as brushed products, it has an extremely high risk of damaging the fabric material even if tentatively applied, not actually used.
　Moreover, the references 4 and 5, although a special polishing method is taught, these polishing method is a technique applied to a brushed product. The spun yarn of synthetic fibers, fluff hard, since the fluff (bristles) escapes be polished, it is difficult to process only fluff causes no pilling occurrence compromising the material fabric.
　Thus, as the pilling measures in textile products in general, singeing, reduction of fiber strength, grinding, shearing (shaved processing, pruning), a method of modifying such a fiber material is known, synthetic fibers the pilling measures woven or knitted fabric using yarn, since both are inadequate choice of using the spun yarns of synthetic fibers in the discussion stage of garment development tend to be excluded.
　Also, surprisingly, the finishing process which is a combination of polishing and singeing as pilling measures woven or knitted fabric using a yarn of synthetic fibers are not known and have not been carried out to date.
CITATION
Patent Document
[0016]
Patent Document 1: JP-A-8-144158
Patent Document 2: JP-B 61-31234 Patent Publication
Patent Document 3: JP 2004-197243 Patent Publication
Patent Document 4: JP-A 9-95859 Patent Publication
Patent Document 5: JP 7-97764 JP
Patent Document 6: JP 2016-108702 Patent Publication
Summary of the Invention
Problems that the Invention is to Solve
[0017]
　In view of the current state of the prior art described above, an object of the present invention is to provide a fabric comprising staple fibers of thermoplastic synthetic fibers, for example, the generation of pilling in woven or knitted fabric is suppressed, and reduction in strength and texture of the fabric woven or knitted fabric worsening is suppressed, and to provide a manufacturing method thereof.
Means for Solving the Problems
[0018]
　The present inventors, the problems intensive studies to solve the result of repeated experiments, the fuzz the short fibers obtained by weaving or knitting using a yarn comprising a short fiber of thermoplastic synthetic fibers as yarn at least one surface of the woven or knitted fabric having a melting ball formed on the end of the short fibers by singeing, thereafter, the molten ball of fluff tip of the short fibers formed, for example, a roll grinding machine or belt by forming the grinding marks and abraded by polishing using sander polishing machine, excellent pilling resistance is extremely, the production phase and repeating weave deterioration of strength reduction and texture of the fabric by the use has been inhibited or knitted fabric obtained in which unexpected and have completed the heading present invention to the.
[0019]
　That is, the present invention is of follows.
　[1] A pilling fabric comprising staple fibers of thermoplastic synthetic fibers on at least one surface of the fabric, and the molten ball of the short fiber ends, polishing streaks of molten ball of fluff tip of the short fibers the pilling fabric characterized by having and.
　[2] The thermoplastic synthetic fibers are polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, a fiber selected polyvinyl alcohol, polyolefin, and from the group consisting of polyurethane, pilling fabric according to [1].
　[3] is a woven or knitted fabric, pilling fabric according to [1] or [2].
　[4] JIS L 1930 C4M method 10 washes in accordance with (tumble used), and after 30 times, the pilling grade according to (a method using ICI type tester) JIS L 1076 A method, both are tertiary or , pilling fabric according to [3].
　[5] the following steps:
　using a spun yarn containing long fiber yarn and / or staple fibers of thermoplastic synthetic fibers as yarn, fabrics having fuzz fluff or the short fibers cut ends of the long fiber yarn weaving or knitting step;
　obtained at least one side surface and singeing to form a molten ball on the end of the cutting edge or the short fibers of the long fiber yarn step of the fabric; and
　the resulting one side of the fabric ; forming a grinding marks and abraded by polishing the molten ball of fluff tip of the cutting edge or the short fibers of the long fiber yarn formed on the surface
pilling fabric manufacturing method comprising.
　[6] The thermoplastic synthetic fibers are polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, a fiber selected polyvinyl alcohol, polyolefin, and from the group consisting of polyurethane, the method according to [5].
　[7] The pilling fabric is woven or knitted fabric, the method according to [5] or [6].
　[8] The pilling fabric JIS L 1930 C4M method 10 washes in accordance with (tumble used), and after 30 times, pilling grade according to (a method using ICI type tester) JIS L 1076 A method, both it is tertiary or method according to [7].
The invention's effect
[0020]
　Pilling fabric comprising staple fibers of thermoplastic synthetic fibers according to the present invention, the molten ball is left by singeing inside fabric, the fabric surface only polishing streaks of molten ball of fluff tip of the short fibers are present Therefore, good pilling resistance is very, and after the manufacturing stage and repeated use and also significant strength reduction, fabric texture deterioration is suppressed, for example, a woven or knitted fabric. Therefore, the present invention allows the application of various clothing and to other textile products, hitherto woven or knitted fabric using a spun yarn of a synthetic fiber is difficult to put into practical use with the desired texture and appearance. Unless the type of synthetic fibers used as raw yarn is a thermoplastic, it is possible to choose freely without limiting in any way. The present invention is also applicable to woven or knitted fabric or the like subjected to raising treatment. Furthermore, it is also applicable to woven or knitted fabric or the like having weaving woven or knitted fabric of the long fibers, the fibers having an end the long fibers are cut at knitting or the like to the surface. Therefore, pilling fabric comprising staple fibers of thermoplastic synthetic fibers according to the present invention, for example, while having a soft texture, such as natural fibers, providing durable clothing lighter than natural fibers and, repeating also allows the application to a variety of textile products such as a cover for a strong and does not easily deteriorate sheets and bedding you use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
FIG. 1 is an electron micrograph of a fabric surface after washing 10 times the finished products span polyester plain weave fabric prepared in Comparative Example 1 (Regular workpiece).
FIG. 2 is an electron micrograph of the fabric surface after washing 30 times of the finished products span polyester plain weave fabric prepared in Comparative Example 1 (Regular workpiece).
FIG. 3 is an electron micrograph of a fabric surface after washing 10 times the finished products span polyester plain weave fabric prepared in Example 1 (singeing + polishing).
FIG. 4 is an electron micrograph of the fabric surface after washing 30 times of the finished products span polyester plain weave fabric prepared in Example 1 (singeing + polishing).
FIG. 5 is an electron micrograph of the fabric surface immediately subjected to singeing process after desizing refining greige process of producing a spun polyester plain weave fabric prepared in Example 1 (singeing only).
6 is an electron micrograph of immediately after the fabric surface finish of the finished product of the span polyester plain weave fabric prepared in Example 1 (singeing + polishing).
7 is an electron micrograph of the fabric surface of the finished products span nylon plain weave fabric of Comparative Example 3 (Regular workpiece) (Regular workpiece).
8 is an electron micrograph of immediately after the fabric surface finish of the finished product of the span nylon plain weave fabric of Example 2 (singeing + polishing).
9 is an electron micrograph of the fabric surface immediately subjected to singeing process after desizing refining greige process of producing a spun nylon plain weave fabric of Example 2 (singeing only).
It is a schematic diagram showing an example of FIG. 10 belt sander polishing machine of an apparatus for forming a grinding marks and abraded by polishing the molten ball of fluff tip after singeing.
DESCRIPTION OF THE INVENTION
[0022]
　Hereinafter, an embodiment of the present invention in detail.
　1 embodiment of the present invention is a pilling fabric comprising staple fibers of thermoplastic synthetic fibers on at least one surface of the fabric, and the molten ball of the short fiber ends, fluff tip of the short fibers and having a polishing marks of the molten ball, said an anti-pilling fabric.
[0023]
　In the present specification, the term "thermoplastic synthetic fibers", as long as it melted molten ball is formed by gas singeing, etc., it is not particularly limited, and can be chemically synthesized polymer chemistry fibers, such as polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, synthetic fibers polyurethane or the like. For example, the melting point of the short fibers of polyester fibers was 255 ~ 260 ° C., the melting point of the short fiber of nylon is a polyamide fiber is 215 ° C. ~ 220 ° C., the melting point of the poly acrylic fiber is not clear but the softening point is 190 ~ 240 ° C., the melting point of the short fibers of polypropylene which is polyolefin-based fiber is 165 ~ 173 ° C.. Contrary to this, cotton is a natural fiber (Upland) decomposes at 235 ° C., burned in 275 ~ 456 ° C., wool (Merino) is pyrolyzed at 130 ° C., burnt at 205 ° C., carbonized at 300 ° C.. Also, a regenerated cellulose fibers, rayon or cupra is softened, not melted, starts to colored decomposed at 160 ℃ ~ 300 ℃. Thermoplastic synthetic fibers in the present embodiment, polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and preferably fibers selected from the group consisting of polyurethane, more preferably polyester, a polyamide or polyacrylic fibers.
[0024]
　Herein, the term "staple fiber" refers to short fibers (staple) which are cut with a short length, in the case of short fibers of thermoplastic synthetic fibers is made as a generally long fiber (filament) and it is obtained by cutting the thing. The length of the short fibers from the viewpoint of spinning workability, preferably 20 ~ 70 mm, more preferably 30 ~ 60 mm, more preferably from 38 ~ 51 mm. The fineness of the short fibers (single fiber fineness), from the viewpoint of holding strength of the spinnability and the fabric is preferably 0.01 to 10 denier, more preferably 0.8 to 5 denier, more preferably from 1.0 to 2. it is a 5 denier. Single fiber fineness is less than 0.01 denier, dirt easily, easily make pill fluff occurs tip focused, while in 10 denier greater, but less is generation of fluff, strong increases because, once the resulting pill is less likely to fall off, feeling even worse. Short fiber cross-sectional shape may be a modified cross section may be round cross-section.
　Incidentally, herein, the term "short fibers", weaving using a long fiber of the thermoplastic synthetic fibers as yarn, or the like on the surface of the resulting greige by knitting, the weaving, knitting, by napping treatment such as generated as a result of the long fibers are cut, also encompasses fibers having a cut end.
[0025]
　Herein, the term "yarn (spun yarn)" is loosen short fibers, arranged fibers as Kushikezuru refers to yarn that bundled twisted. Spun yarn, in view of the molten ball formed, but is preferably one composed of only short fibers of a kind of thermoplastic synthetic fibers, may be a mixed yarn of staple fibers of two or more of thermoplastic synthetic fibers. May also be a blended yarn with short fibers and other natural fibers of the thermoplastic synthetic fibers, composite fiber yarn, 交撚 yarn with filament yarn may be a fine 紡合 twine. Count of spun yarn 7-120 fastest (760-44 denier) is preferred. If it is less than 7 fastest a fabric thickness, strength is lowered at 120 fastest greater. In addition, the number of twist is, 60 to 1500 times / m is preferable.
[0026]
　In the present specification, the term "fabric" is, woven, knitted fabric (circular knitted fabric, warp knitted fabric, weft knitted fabric), it may be any of a non-woven fabric. From the viewpoint of exhibiting the desired effects as clothing products, woven or knitted is preferably a fabric. Fabric is preferably one composed of 100% yarn spinning long fibers in the warp, union prepared by using the spun yarn in the weft is also preferable for the texture with resilience is obtained in software. Weave, knit organization is not particularly limited. Furthermore, herein, refers to a woven or knitted The term "woven or knitted fabric".
[0027]
　Herein, the term "fluff" refers to the end of the short fibers napped from the fabric surface, the ends of the short fibers present in the interior of the fabric within or configuration spun yarn not say the fluff. 1 and 2, the fluff example of polyester, and in FIG. 7, showing the fluff example of nylon.
[0028]
　Herein, the term "melt ball" is fluff thermoplastic synthetic fibers are melted by singeing, it refers to a variation in a substantially spherical shape. In the present embodiment, the molten ball that existed on the surface of the fabric is converted into the polishing streaks by abrasion due to polishing. 5, an example of a molten ball of polyester, FIG. 9 shows an example of a molten ball of nylon.
[0029]
　Herein, the term "polishing streaks" refers to the end of the short fibers of a shape having traces molten ball fabric surface is abraded by polishing. Figure 3, 4, 6, an example of the polishing marks of the polyester, and FIG. 8 shows an example of a polishing streaks nylon.
[0030]
　Another embodiment of the present invention comprises the following steps:
　an original using a spun yarn comprising short fibers of thermoplastic synthetic fibers as a yarn, a step of weaving or knitting a fabric having a nap of the short fibers;
　resulting woven and, at least one side surface by singeing to form a molten ball of the end of the short fibers steps of knitting
　by polishing molten ball of fluff tip of the short fibers formed on the one surface of the resultant woven or knitted fabric forming a abraded by grinding marks;
a pilling fabric manufacturing method comprising.
　Hereinafter, an example of manufacture of an anti-pilling fabric according to the present embodiment.
　Short fibers of thermoplastic synthetic fibers to yarn. At that time, it may be a mixed yarn of two or more thermoplastic synthetic fibers, or one or more thermoplastic synthetic fibers and may be blended yarn with one or more natural fibers.
　Then, weaving with the spun yarn as the warp and / or weft, to greige.
　Then, subjected to a desizing refining the raw machine.
[0031]
　Next, apply the following singeing.
(Singeing)
　to form a molten ball on the fluff tip present on the fabric surface. At this time, although buried inside the fabric, although in some cases may also molten ball on the end of the short fibers that are outside of the spun yarn, molten ball present in such sites do not appear on the fabric surface, the fabric there is no possibility that the poor texture of. Singeing, for example, it can be done by direct singeing by flame from a gas burner indirect singeing due to contact with the (gas singeing) and / or heating roller (contact singeing). Polyester and nylon, since the melting point is at 210 ~ 260 ° C., direct singeing is preferred. For higher material melting point, indirect singeing the heat is conducted preferably in a short time in which the temperature of the heating roller to a higher temperature. Although singeing conditions is not particularly limited, only to be allowed to form a molten ball on the fluff destination present on the fabric surface as a cause of pilling. Passing speed of the fabric to be supplied to the singeing process (singeing processing speed) is preferably 60 ~ 120 m / min, more preferably 80 ~ 100 m / min. Incidentally, the spun yarn when including natural fibers, if burn out the fluff natural fibers carbonized by gas singeing, gas singeing for pilling is suppressed are preferred.
[0032]
　Then, subjected to the polishing of the following.
(Polishing)
　by the singeing, melting ball of fluff tip of the short fibers is formed on at least one surface woven or knitted fabric, for example, is abraded, grinding marks are formed by polishing using abrasives or abrasive paper . If both sides of the fabric molten ball is formed preferably performed for also double-side polishing. The polishing method may be using a variety of polishing machine also manually. The polishing machine may be used a roll grinding machine which imparts abrasive to the roll, the roll grinding machine wound abrasive paper to roll, a belt sander grinder using a belt-shaped polishing paper. 10 shows an example of a polishing apparatus using the belt sander polishing machine. For polishing both surfaces of the fabric by using a belt sander polishing machine may be performed twice by replacing the polished surface. As shown in FIG. 10, the fabric after singeing is preheated in the heat cylinder through the reverse roller (1, 2) (3-5), through the reverse roller (6-8), belt sander rotating (10), the movable holding valve (9), while adjusting the strength of pressing, is pressed against the molten ball of the fabric surface is abraded, grinding marks are formed. Is produced by polishing powder, powder removing paper (11) is removed by fabric dust removing (12, 14), the fabric finally polishing powder is removed by folding the spun off device (19) recovered It is.
[0033]
　The pilling measures by the conventional polishing, for example, as described in Patent Document 5, minutes 繊化 but was to (fibrillation) to the polishing in the present embodiment, the molten ball that caused by singeing it is intended to apply to scraping. 5, as shown in FIG. 9, since the molten ball is to take the form of substantially spherical having a predetermined size, abrasives or abrasive paper is brought into contact with the fabric surface, the scraping, it melted ball is entering the inner fabric can not be preferentially polished, it is rubbing, damage to the ground structure of the fabric is minimized. Therefore, such a polishing fabric thermoplastic synthetic fused ball which was a singeing of the biggest problems of the fibers due to the remaining fabric roughness, addresses the problem that the texture of and appearance deterioration, further fabric strength reduction can be suppressed. As described above, in the cited document 4 and 5, although a special polishing method is taught, these polishing method is a technique applied to a raising products, the spun yarn of the synthetic fibers, fluff hard, because fluff be polished (bristles) to escape, it is difficult to process only fluff causes no pilling occurrence compromising the material fabric. However, the present inventors, if fluff molten ball at its distal end by singeing is formed, it becomes difficult to escape, without impairing the material fabric, it is possible to polish the molten ball by rubbing, anti It found that it is possible to produce a very good fabric pilling has been led to completion of the present invention. Further, as described above, since the cited reference 3, although the molten ball by singeing synthetic fibers is described, such as whether it is removable with shearing, shearing is originally a method reaps brushed fibers, it is practically difficult to apply to other cases as well as brushed products polishing, has an extremely high risk of damaging the fabric material even if tentatively applied, not actually used.
[0034]
(Napped)
　manufacturing method of an anti-pilling fabric of this embodiment is also applicable to the textile fabric or the like having undergone surface a napped. Weaving using spun yarn comprising short fibers of thermoplastic synthetic fibers as yarn, as the method for the surface of the fabric knitted etc. napped state, for example, clothing raising treatment, processing methods such as emery raising treatment, pile fabrics weaving method in accordance with, such as, method, and the like by the organization, such as the fabric according to the double raschel knitted fabric of the center cut. At least one side surface singeing to the molten ball is formed at the end of the short fibers, fluff of the short fibers which are formed on one surface of such obtained woven or knitted fabric in which the knitting such as woven having undergone surface a napped the molten ball of the tip may be formed grinding marks and abraded by polishing.
　The manufacturing method of an anti-pilling fabric of this embodiment, woven using a long fiber of the thermoplastic synthetic fibers as yarn, on the surface of the knitting such as the greige, weaving, knitting, long fibers are cut by napping treatment such as as a result, can be applied to the woven or knitted fabric or the like which led to short fibers is present. This is because, if there is an end of the fiber on one side surface of the dough, the molten ball is formed on the end portion of the fiber by singeing, melting of fluff tip formed on one surface of the resultant woven or knitted fabric and abraded by polishing the ball to form a grinding marks is because it is possible to achieve the desired effect.
[0035]
(Heat set)
　then subjected to heat treatment in order to eliminate the effects of non-uniform thermal history of the synthetic fibers. Performing thermal set is preferred in order to achieve dimensional stability and uniform dyeing of the fabric. For polyester fiber and nylon fiber, a heat treatment of about 30 seconds to 1 minute at 180 ° C..
[0036]
(Staining)
　is not particularly limited to staining. The staining, there is a continuous dyeing and dip dyeing (fir dyed), dyeing is common. While some continuous dyeing for polyester is carried out, texture cured flexibility is impaired. In dyeing, but results in a dyeing group different molten ball and the land of dyeability and performs singeing before dyeing, in the present embodiment, since the molten ball of the fabric surface is removed by polishing, dyeing team occurs there is no problem that. Singeing the dyeing muscle occurs as heterogeneous. If you really can not resolve the dyed muscle by singeing, after dyeing the yarn, it may be subjected to singeing and polishing the fabric, that is, may be any of singeing before staining and singeing after staining.
(Finish drying)
　then finish dry.
[0037]
　Woven or knitted fabric of pilling measures have been subjected by the manufacturing method described above, since the through singeing step and the polishing step, 3, 4, 6, as shown in FIG. 8, when confirmed by an electron microscope, the fabric While buried therein outside of the spun yarn, the melt ball of the short fiber ends, melting ball of fluff tip is present polishing streaks caused been abraded on fabric surfaces.
　By applying pilling measures, including the the singeing step and the polishing step, even pilling grade 1-2 grade woven or knitted fabric comprising the staple fiber of thermoplastic synthetic fibers, this pilling grade tertiary or more, preferably 4 or higher grade, more preferably can be grade 5, also the deterioration of reduction and texture strength can be woven or knitted fabric that has been suppressed. Woven or knitted fabric subjected to pilling measures of this embodiment, as shown in the following examples, even after repeated washing pilling performance since sustained, has excellent durability.
Example
[0038]
[Example 1] span polyester product (singeing + polishing product) production of
　spun polyester fibers (short fibers of polyester fiber, 1.6 denier, 38mm cut) was spun by a conventional method, the polyester yarn (30 cotton count) It was obtained.
　Obtained is warped polyester spun yarns as warp, this is the warping has been warp glued to Keinori mainly composed of Poval, by using polyester spun yarn also obtained a weft, warp density 90 yarns / inch (2.54 cm), and weaving the greige plain weave with weft density 70 yarns / inch.
　After the resulting greige desizing refining, and singeing the fabric both sides with gas singeing machine (80 m / min), to form a molten ball on the fabric. Then, polished on both sides of the fabric in the belt sander (mesh # 1000) to remove the molten ball caused on fabric surfaces. Thereafter, 180 ° C., to obtain a thermal setting step of 1 minute, fir dyeing step by dyeing, and a drying step a plain weave test anti comprised spun polyester fibers.
[0039]
[Comparative Example 1] span polyester products (regular processed products) manufacturing
　but omitting the singeing process and polishing process to obtain a test anti in the same manner as in Example 1.
[0040]
[Comparative Example 2] Span polyester product (singeing + loss workpiece) manufacturing
　after singeing process of Example 1, in place of the polishing process, except subjected to caustic treatment (10%) as in Example 1 to obtain a test anti-by manner.
[0041]
[Comparative Example 3] Span polyester products production of (singeing + loss workpiece)
　after singeing process of Example 1, in place of the polishing process, except subjected to caustic treatment (20%) as in Example 1 to obtain a test anti-by manner.
[0042]
[Comparative Example 4] Span polyester products production of (singeing + loss workpiece)
　after singeing process of Example 1, in place of the polishing process, except subjected to caustic treatment (30%) as in Example 1 to obtain a test anti-by manner.
[0043]
Example 2 Span nylons (singeing + polishing article) preparation of
　1.7 denier spun nylon fiber (short fiber of nylon 66 fibers), spun and 38mm cut) according to a conventional method, the nylon yarn (30 to obtain a count).
　Obtained is warping nylon yarn as warp, the warping is in the warp and glued Keinori mainly composed of Poval, using same nylon spun yarn obtained weft, warp density 90 yarns / inch was woven greige plain weave with weft density 70 yarns / inch.
　After the resulting greige desizing refining, and singeing the fabric both sides with gas singeing machine (80 m / min), to form a molten ball on the fabric. Then, polished the fabric both sides with a belt sander (mesh # 1000) to remove the molten ball caused on fabric surfaces. Thereafter, 180 ° C., to obtain a thermal setting step of 1 minute, fir dyeing step by dyeing, and a drying step of the test anti composed of spun nylon fiber.
[0044]
[Comparative Example 5] Span nylons (regular processed products) manufacturing
　but omitting the singeing process and polishing process to obtain a test anti in the same manner as in Example 2.
[0045]
Example 3 blend brushed material product (singeing + polishing product) of manufacturing
　polyester fibers (38mm cut top iodide) and rayon fibers (38mm cut) blended yarn was spun at a mixing ratio of 65:35 (40 cotton count) 2 this polyurethane filament yarn (40 denier) yarn twisting consisting one (final mixing ratio 61: 33: 6) was used as a warp and weft to prepare the woven has been dyed fabric (96 × weft 90 present after) further subjected to needle cloth brushed. Gas singeing the (80 m / min) applied to the fabric, to form a molten ball, then polished to the fabric both sides with a belt sander (mesh # 1000) to remove the molten ball caused on fabric surfaces. Thereafter, 180 degrees, to obtain a composed plain weave test reaction from fabric blend through one minute of heat-setting process.
[0046]
Preparation of Comparative Example 6 blend brushed material product (singeing workpiece)
　but omitting the grinding process to obtain a test anti in the same manner as in Example 3.
[0047]
Preparation of Comparative Example 7 blend brushed material products (regular processed products)
　but omitting the singeing process and polishing process to obtain a test anti in the same manner as in Example 3.
[0048]
　Using the test anti obtained in Examples 1-3 and Comparative Examples 1-7, without washing, after washing 10 times, samples for after washing 30 times, anti-pilling tests were conducted tear strength test. However, Example 2, Comparative Example 5, omitting the strength test tear for testing anti obtained in Example 3, for testing anti obtained in Comparative Example 6 and 7, after washing 10 times, washing 30 anti-pilling test after times were also omitted. The results shown in Table 1 below.
　Pilling test was carried for 10 hours in accordance with JIS L 1076 A method (with ICI type tester). The test results were the average of the test piece four determination results.
　Tear strength test in accordance with JIS L 1096 D (pendulum method).
　Laundry, 10 times in accordance with JIS L 1930 C4M method (tumble use), was carried out for 30 times.
[0049]
[Table 1]

[0050]
　From Table 1, anti-tests Examples 1-3, by going through the singeing and polishing, pilling grade is grade 5 is the best value even after washing 30 times, pilling resistance is extremely excellent, texture is also good, there was no decrease in strength. On the other hand, pilling grade test anti of Comparative Example 1 prepared without a singeing and polishing primary, testing anti Comparative Example 5 pilling grade 1.5 grade, in Comparative Example 7 Test anti pilling grade is primary, numerous pilling occurs at the manufacturing stage.
　In Comparative Examples 2 to 4 shown the results from caustic treatment known as pilling measures spun polyester fibers from a conventional, pilling grade, preferred result that likewise Grade 5 Example 1 and 2 Although obtained, the result of a strong test has fallen to less than that or about 50% of the example 1, significant strength degradation of the fabric was observed. For this reason, it has been difficult to maintain the strength and texture inherent to the fabric as a material. Furthermore, the pilling measures by reduction processing, the difference in weight loss, easily out variations in texture and strength, was not preferable from the viewpoint of stable pilling measures. In Comparative Example 6, pilling grade is 3.5 grade, but pilling resistance is improved compared to Comparative Example 7, the melted ball caused by singeing there are many on the fabric surface, the touch of the fabric worse, was intended to detract from the commercial value.
Industrial Applicability
[0051]
　Pilling fabrics of the present invention is excellent pilling resistance is very, texture is good, since there is no significant reduction in strength, a variety of clothing and other textile products with the desired texture and appearance, heretofore commercialized as woven or knitted fabric using a spun yarn of a synthetic fiber it is difficult, it is suitably used.
DESCRIPTION OF SYMBOLS
[0052]
　1 reverse roller
　2 reverse roller
　3 heat cylinder
　4 Thermal Cylinder
　5 thermal cylinder
　6 reverse roller
　7 reverse roller
　8 reverse roller
　9 movable holding valve
　10 belt sander
　11 paper powder removing
　12 fabric dust removing
　13 reverse roller
　14 fabric powder removing
　15 reverse roller
　16 guide roller
　17 guide roller
　18 reverse roller
　19 shaken off device

WE claims

[Requested item 1]
　A pilling fabric comprising staple fibers of thermoplastic synthetic fibers on at least one surface of the fabric, having a melting ball of the short fiber end and the polishing marks of the molten ball of fluff tip of the short fibers the pilling fabric, characterized in that.
[Requested item 2]
　The thermoplastic synthetic fibers are polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, a fiber selected polyvinyl alcohol, polyolefin, and from the group consisting of polyurethane, claim 1 anti-pilling fabric according to.
[Requested item 3]
　A woven or knitted fabric, pilling fabric according to claim 1 or 2.
[Requested item 4]
　JIS L 1930 C4M method 10 washes in accordance with (tumble used), and after 30 times, the pilling grade according to (a method using ICI type tester) JIS L 1076 A method is both grade 3 or more, claim anti-pilling fabric according to 3.
[Requested item 5]
　Following steps:
　yarns as thermoplastic synthetic fibers using the spun yarn containing long fiber yarn and / or staple fibers, woven or knitted fabrics having fuzz fluff or short fibers cut ends of the long fiber yarn or prepared to process;
　and; the resulting step to form a molten ball and at least one side surface singeing cut end or the short fiber ends of the long fiber yarn of the fabric
　forming the resulting fabric side surface of the ; it has been forming a grinding marks and abraded by polishing the molten ball of fluff tip of the cutting edge or the short fibers of the long fiber yarn
pilling fabric manufacturing method comprising.
[Requested item 6]
　The thermoplastic synthetic fibers are polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and a fiber selected from the group consisting of polyurethane, claim 5 the method according to.
[Requested item 7]
　The pilling fabric is woven or knitted fabric A process according to claim 5 or 6.
[Requested item 8]
　The pilling fabric JIS L 1930 C4M method 10 washes in accordance with (tumble used), and after 30 times, JIS L 1076 A method pilling grade according to (a method using ICI type tester) are both Grade 3 or higher in a method according to claim 7.