Pile Fabric With Height Difference and Method for Manufacturing the Same

Abstract

A step pile fabric according to the present invention contains a non-shrinkable fiber, and a shrinkable fiber containing a modacrylic copolymer. A composition of the shrinkable fiber containing the modacrylic copolymer contains a polymer composition obtained by mixing i) 60 to 99 parts by weight of a copolymer (A) containing 35 wt % to 98 wt % of acrylonitrile, and 2 wt % to 65 wt % of a total amount of 0.5 wt % to 5.0 wt % of a sulfonic-group-containing monomer and other vinyl monomer, and ii) 1 to 40 parts by weight of a copolymer (B) containing 0 wt % to 90 wt % of acrylonitrile, 2 wt % to 40 wt % of a sulfonic-group-containing monomer, and 0 wt % to 80 wt % of other vinyl monomer containing no halogen. A dry heat shrinkage S of the shrinkable fiber at 130° C. for 5 minutes after dyeing is 15% to 40%. In this way, by performing dyeing using a cationic dye in a low-temperature region so as to suppress shrinkage during dyeing and performing a dry heat treatment after dyeing, a pile fabric with large height difference is provided.

1 - 9 . (canceled)  
     
     
         10 . A method for manufacturing a step pile fabric comprising a non-shrinkable fiber and a shrinkable fiber comprising a modacrylic copolymer, a composition of the shrinkable fiber comprising the modacrylic copolymer being a polymer composition obtained by mixing 
 i) 60 to 99 parts by weight of a copolymer (A) comprising 35 wt % to 98 wt % of acrylonitrile, and 2 wt % to 65 wt % of a total amount of 0.5 wt % to 5.0 wt % of a sulfonic-group-containing monomer and other vinyl monomer, and    ii) 1 to 40 parts by weight of a copolymer (B) comprising 0 wt % to 90 wt % of acrylonitrile, 2 wt % to 40 wt % of a sulfonic-group-containing monomer, and 0 wt % to 80 wt % of other vinyl monomer containing no halogen, the method comprising:    dyeing the shrinkable fiber comprising the modacrylic copolymer at T° C.;    dyeing the non-shrinkable fiber;    manufacturing a pile fabric by using the dyed shrinkable fiber comprising the modacrylic copolymer and the dyed non-shrinkable fiber; and    subjecting the pile fabric to a heat treatment;    wherein a dry heat shrinkage S of the shrinkable fiber at 130° C. for 5 minutes after the dyeing at T° C. satisfies Formula (1) below and is 15% to 40%,      70−0.726 T≦S (%)≦85−0.726 T  (where 60 ≦T≦ 85)  (1),    where dry heat shrinkage S (%)=100×(1−fiber length after shrinkage/fiber length before shrinkage).    
     
     
         11 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the shrinkable fiber is dyed with a cationic dye.  
     
     
         12 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the product of the dyeing temperature T° C. and a dyeing time H minutes (T×H) ranges from 1800 to 5100.  
     
     
         13 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the height difference is produced by mixing the non-shrinkable fiber and the shrinkable fiber at a weight ratio of 5:95 to 80:20, performing sewing, pre-polishing and pre-shirring, and then performing a dry heat treatment at 110° C. to 150° C.  
     
     
         14 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the non-shrinkable fiber is a fiber whose dry heat shrinkage at 130° C. for 5 minutes is smaller than 10%.  
     
     
         15 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the non-shrinkable fiber is a modacrylic non-shrinkable fiber.  
     
     
         16 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the dry heat shrinkage S of the shrinkable fiber of the step pile fabric in a dry heat treatment at 110° C. to 150° C. using a pin tenter drier is in a range of 15% to 40%.  
     
     
         17 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the sulfonic-group-containing monomer in the copolymers (A) and (B) is at least one selected from the group consisting of sodium allylsulfonate, sodium methallylsulfonate, sodium vinylsulfonate, sodium styrenesulfonate and sodium 2-acrylamido-2-methylpropanesulfonate.  
     
     
         18 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the other vinyl monomer in the copolymer (A) is at least one selected from the group consisting of vinyl halides, vinylidene halides, acrylic acids or alkyl esters thereof, methacrylic acids or alkyl esters thereof, vinyl acetate, acrylamide, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, glycidyl methacrylate and glycidyl acrylate.  
     
     
         19 . The method for manufacturing a step pile fabric according to  claim 10 , wherein the other vinyl monomer containing no halogen in the copolymer (B) is at least one selected from the group consisting of acrylic acids, methacrylic acids or alkyl esters thereof, vinyl acetate, acrylamide, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, glycidyl methacrylate and glycidyl acrylate.  
     
     
         20 . A step pile fabric comprising a non-shrinkable fiber, and a shrinkable fiber comprising a modacrylic copolymer; 
 wherein a composition of the shrinkable fiber comprising the modacrylic copolymer comprises a polymer composition obtained by mixing 
 i) 60 to 99 parts by weight of a copolymer (A) comprising 35 wt % to 98 wt % of acrylonitrile, and 2 wt % to 65 wt % of a total amount of 0.5 wt % to 5.0 wt % of a sulfonic-group-containing monomer and other vinyl monomer, and  
 ii) 1 to 40 parts by weight of a copolymer (B) comprising 0 wt % to 90 wt % of acrylonitrile, 2 wt % to 40 wt % of a sulfonic-group-containing monomer, and 0 wt % to 80 wt % of other vinyl monomer containing no halogen, and  
   wherein a dry heat shrinkage S of the shrinkable fiber at 130° C. for 5 minutes after dyeing is 15% to 40%.    
     
     
         21 . The step pile fabric according to  claim 20 , wherein the shrinkable fiber is dyed with a cationic dye.  
     
     
         22 . The step pile fabric according to  claim 20 , wherein the non-shrinkable fiber is a fiber whose dry heat shrinkage at 130° C. for 5 minutes is smaller than 10%.  
     
     
         23 . The step pile fabric according to  claim 20 , wherein the non-shrinkable fiber is a modacrylic non-shrinkable fiber.  
     
     
         24 . The step pile fabric according to  claim 20 , wherein a weight ratio of the non-shrinkable fiber to the shrinkable fiber is 5:95 to 80:20.  
     
     
         25 . The step pile fabric according to  claim 20 , wherein the dry heat shrinkage S of the shrinkable fiber in a dry heat treatment at 110° C. to 150° C. is in a range of 15% to 40%.  
     
     
         26 . The step pile fabric according to  claim 20 , wherein the sulfonic-group-containing monomer in the copolymers (A) and (B) is at least one selected from the group consisting of sodium allylsulfonate, sodium methallylsulfonate, sodium vinylsulfonate, sodium styrenesulfonate and sodium 2-acrylamido-2-methylpropanesulfonate.  
     
     
         27 . The step pile fabric according to  claim 20 , wherein the other vinyl monomer in the copolymer (A) is at least one selected from the group consisting of vinyl halides, vinylidene halides, acrylic acids or alkyl esters thereof, methacrylic acids or alkyl esters thereof, vinyl acetate, acrylamide, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, glycidyl methacrylate and glycidyl acrylate.  
     
     
         28 . The step pile fabric according to  claim 20 , wherein the other vinyl monomer containing no halogen in the copolymer (B) is at least one selected from the group consisting of acrylic acids, methacrylic acids or alkyl esters thereof, vinyl acetate, acrylamide, 2-hydroxyethyl methacrylate, 2-hydroxyethyl acrylate, glycidyl methacrylate and glycidyl acrylate.