THREE-DIMENSIONAL CLOTH WITH SPECIAL STRUCTURE AND PROCESS FOR ITS PRODUCTION

Abstract: New cloth is a three-dimensional cloth with a special structure where gps. of raised fibres are unified at their tips in a flattened form to give scaly structures which cover the cloth surface layer. Prodn. of the cloth comprises subjecting a raised fibre layer having many raised fibers to thermal pressing treatment to adhere the tips of the raised fiber surface layer in a large area to form a film, and crumpling it to split into smaller units to form numerous scaly structures.

Description: The present invention relates to a new fabric which is rich in a new, unparalleled raw material feeling, a fashionable feeling and an unexpected feeling. In more detail, the present invention relates to a three dimensional fibrous fabric having a new structure having many scaly structures covering the surface layer of the fabric and to its method of preparation. US-A-4190572 discloses a leather-like sheet prepared by coating a porous sheet, for example of fibrous material, with a non-porous layer of polyurethane elastomer. The appearance and hand of the sheet is improved by crumpling. Such sheets do not have a pile surface and the non-porous layer apparently remains continuous. As will be described in more detail below, fabrics in accordance with the invention are in no way similar to these. Indeed, it is believed that no fabric similar to those of the invention has ever been seen before. The closest would be a fabric prepared by embossing a fabric having a scaly structure such as an embossing treatment of an artificial leather and followed by an enamel treatment on the surface. However, in such a conventional fabric, the surface and cross-sectional structures have poor cubic effects. It looks artificial and a natural feeling is scarce because the surface shape is in a regular manner. The feeling is very rough and hard and it looks paper-like. Technological problems which the present invention seeks to solve are the need for a new fabric which is rich in a new raw material feeling which has been unparalleled and has an unexpected feeling and at the same time a fashionable feeling, and the need for a method for preparing such a fabric. The present invention provides a three dimensional fabric comprising a base fabric and pile fibres projecting from the base fabric, apexes of which pile fibres together define a pile surface, characterised in that, in respective adjacent regions of the pile surface, the apexes of the pile fibres are joined together in side-by-side relationship to provide respective substantially continuous surface parts which said substantially continuous surface parts are at least partly separate from one another, whereby the pile surface comprises a plurality of adjacent said surface parts. In other words, in the fabric of the present invention a fibrous mass consisting of a number of the apexes of adjacent pile fibres joined together provides a surface part in the form of a scale-like body and a mass of such scale-like bodies provides a scale-like structure covering the surface layer of the fabric. Moreover, the invention also provides a method for preparing the three dimensional fabric having such a unique structure, which method comprises providing a fabric structure comprising a base fabric and pile fibres projecting from the base fabric to define a pile surface, subjecting the fabric structure to a heat and compression treatment, optionally in the presence of an adhesive, so as to join together in side-by-side relationship, apexes of adjacent said pile fibres to form, at the said pile surface, a substantially continuous film defined by the said apexes and subjecting the fabric structure to a crumpling operation so as to break the said film and thereby provide substantially continuous parts of the pile surface which parts are at least partly separate from one another, whereby the three dimensional fabric has the scale-like appearance. Thus, in this method, the piled layer of a piled fabric having a lot of pile fibres is treated by a pressing treatment under heating and compression to cause adhesion, at the pile surface layer, of the apexes of the piles over a wide area so as to construct a unitary body, of a film-like monolithic structure, and thereafter a lot of scaly structures are formed by crumpling the fabric and by splitting the above described film-like monolithic structure into units of small areas. Compared to the conventional products which are easily distinguished as being artificial products, the present invention offers a three dimensional fabric having a new, unique structure and a method for preparing it. It is believed that such a structure has not been seen before as a fibre product. The surface exhibits a scaly structure which has an outer appearance and lustre such that the surface might easily be regarded as that of a natural product, for example, that of a new raw material such as a mineral-like, namely mica-like or coal-like, or bagworm-like surface, or has an outer appearance of the surface skin of a pine tree, and at the same time has an appearance of being three dimensional and is excellent in flexibility. In more detail, the three dimensional fabric having a unique structure offered by the present invention has practical effects as described in the following items (1) to (9) which have not been seen in similar, conventional fabrics. (1) A fabric whose outer appearance exhibits an aspect of being very rich in a natural feeling such as scale-like, mineral-like, bagworm-like, or resembling the surface skin of a pine tree, and having never been seen in a conventional product and being rich in a new raw material feeling and an unexpected feeling, is offered by the scaly structure covering the surface layer of the fabric. (2) The scaly structure covering the surface layer of the fabric gives a characteristic lustre feeling by the phenomenon of reflection of light due to its flat shape and thereby a fabric having aesthetic and fashionable feelings is offered. Such a unique lustre feeling is especially remarkable in a deep colour such as black. (3) Contrary to the outer appearance of the surface which is apparently rough and hard, a fabric which is rich in flexibility is offered. (4) A fibrous fabric whose whole outer appearance is rich in a cubic effect is offered because it is constituted by a three dimensional fabric and forms scaly structures in various areas. Because each scale-like body is constructed from an independent mass of apex parts of the pile fibres, independent movement is possible to some extent and it is therefore possible to obtain changing effects of outer appearance and lustre in accordance with the movement of the fabric while in use. (5) Because the intermediate layer between the bottom of the piles and the inside of the scaly structures consists of many pile fibres, the ratio of vacancy is high, and good heat retaining, flexibility and cushioning characteristics can be obtained by a structure wherein such an intermediate layer exists. (6) Because almost the whole fabric surface is covered with a scaly structure of essentially flat bodies, the fabric repels water and does not allow wind to pass through. Namely, it has both good windbreak performance and water repellency. (7) The fabric has two different characteristics, namely both being rich in rural beauty and having high class, new raw material appearance. (8) It is possible to cut the fabric, for example, by a cutter or scissors in the same way as an ordinary fibrous fabric. Practically no fluff is generated, and it is easy to produce various final manufactured goods. (9) In a case wherein the apex parts of the pile fibres are limited by means of a resin so as to form a surface region comprising a group of fibres in the form of a flat-shaped body, the resultant scaly structure has excellent durability and therefore can retain a new raw material appearance, an unexpected feeling and good, fashionable characteristics. Brief Description of Drawings Figure 1 is a rough diagrammatic representation showing an example of a cross-sectional structure of a three dimensional fabric having the unique structure embodying the present invention. Figure 2 is a rough diagrammatic representation showing the scaly structure of the surface of a fabric embodying the present invention. Figure 3 is a microscopic picture showing an example of a cross-sectional shape of a fabric embodying the present invention. Figure 4 is a microscopic picture enlarging the fabric surface, which shows an example of the outer appearance of the scaly structure of the fabric embodying the present invention wherein the area of a constituent unit is relatively large and the size is not relatively uniform. Figure 5 is a microscopic picture of the fabric surface showing an example of the outer appearance of the scaly structure of a fabric embodying the present invention wherein the area of a constituent unit is relatively small. Figure 6 is a microscopic picture enlarging further a part of the scaly structure of a three dimensional fabric embodying the present invention. Figure 7 is a microscopic picture of the fabric surface enlarging even further a part of the scaly structure shown in Figure 6. A three dimensional fabric having the unique structure of the present invention and its method of preparation will be hereinafter further explained in more detail. The scaly structure in a fabric of the present invention is a structure wherein a group of apexes of a number of pile fibres are formed into a body with a flat shape and exist on the surface layer of the fabric like scales and the fabric of the present invention has many of these scaly structures covering the surface of the fabric layer. As the three dimensional fabric having a unique structure of the present invention, the base fabric structure may be provided by a piled fabric, for example, a double velludo fabric, a chinchilla fabric, woven or knitted fabric using chenille yarns, a piled tricot, any of other warp knitted products, an electric flock or a mechanical flock, but it is not restricted thereto and any fabric having a lot of piles, for example, piled fabric prepared by other methods of preparation, can be used. As shown in Figure 1, the three dimensional fabric 1 embodying the present invention has a structure of three layers, and in the uppermost layer, the first layer 2, the apexes of many piled fibres 3 are formed into a body with a flat shape by a self-adhering action due to heat-fusion of the polymer constituting the piled fibres or by the adhering action of an adhesive when such an adhesive, made, for example, of a resin, is used in parallel. Thus, a substantially continuous pile surface part such as a face part 4 having a discrete area is formed. The ground texture providing the base fabric 5 of the piled fabric structure is the lowermost layer of the three layers and the layer of piled fibres 6 is the intermediate layer. In the intermediate layer, the piled fibres 3 usually exist in an inclined state and stand close together. A number of the above described faces 4 shown in Figure 1 are formed on the surface of the fabric in such a way that they cover the whole area of the fabric as shown in Figure 2. Thus, a scaly structure 7 is formed as a whole by locating a number of faces 4 covering densely the surface with cracks such as crack 8 between the faces 4. Individual faces (scale constituting units) 4 of scaly structures adjoining each other seem, from the outer surface appearance, to be separated completely by a crack 8 from the remaining structure, but in practice they are connected through piled fibres 3, the base fabric 5 and other piled fibres 3. In other words, a number of piled fibres 3 disposed between the scaly structure 7 and the base fabric 5 are inclined in general but stand close together as piled fibres to form an intermediate layer having high ratio of vacancy consisting of a number of piled fibres, and the base fabric 5 secures the piled fibres 3 of the three dimensional fabric 1 of the present invention. The length of the part of piled fibres in the intermediate layer is preferably in the range of 1 to 40 mm sufficiently to exhibit the effect of the above described structure of three layers. Based on this structure, the three dimensional fabric of the present invention has a mass of the scaly structures on its surface layer wherein each scaly structure 7 constituted by a plurality of faces 4 can move independently to some extent from the adjacent scaly structure 7. Because the three dimensional fabric of the present invention has a unique state and structure like this, the outer appearance exhibits an aspect of being very rich in a natural feeling (not seen in conventional products) such as scale-like, mineral-like, bagworm-like, or resembling the surface skin of a pine tree, and when the three dimensional fabric is bent and curved, adjoining scaly structures are separated three-dimensionally and the insides of these scales can be exposed. These unique appearance and movement characteristics of the scaly structure offer a fabric which is rich in a new, raw material feeling, an unexpected feeling and a highly fashionable characteristic. The microscopic picture of Figure 3 is an enlarged cross-sectional view of an example of a fabric having the unique structure of the present invention and shows the actual cross-sectional fabric structure represented diagrammatically in Figure 1. The microscopic picture of Figure 4 shows the outer appearance of an example of a three dimensional fabric having the unique structure of the present invention in which the area of a constituent unit of the scaly structure is relatively large and the size is not relatively uniform. The microscopic picture of Figure 5 illustrates the outer appearance of a fabric having the unique structure of the present invention in which the area of a constituent unit of the scaly structure is relatively small. Microscopic pictures enlarging further and still further, a part of the scaly structure of a fabric having the unique structure of the present invention, are shown respectively in Figures 6 and 7. Moreover, in a three dimensional fabric embodying the present invention, it is preferable that at least in a part of a circumferential boundary part of the scaly structure, a fibrous state partly appears when the surface is in a split state such as when bent. Splits 9, where the fibrous state is exhibited are shown in Figure 2. At such circumferential boundary parts the surface parts provided by the scale-like bodies, namely faces 4, are substantially separated from one another and provide a fibrous state. By controlling the formation of the scaly structure and the state of adhesion with the scale-like bodies provided by adhesion of the apexes of a number of the pile fibres, the perception, associated with the three dimensional fabric of the present invention, that the surface of the fabric is that of a new, raw material or other natural product, can be strengthened. Moreover, the touch does not become especially paper-like, the fabric has flexibility, provides a cubic effect and is therefore fashionable. The three dimensional fabric having the above described unique structure of the present invention can be prepared by using a piled fabric having a number of piled fibres such as the above described double velludo fabrics, for example a single pile or a multi pile, chinchilla fabric, a woven or knitted fabric using chenille yarns, piled tricot, any of other warp knitted piled products, electric flock or mechanical flock as a raw material fabric, carrying out a pressing treatment under heating and compression on the piled layer of the piled fabric to adhere the piled surface layer so that the apexes of the piles together form a unitary, film-like body over a wide area and thereafter crumpling the fabric to split the above described film-like monolithic structure into a number of units of small area and to form thereby a number of scaly structures. The pile length of the piled fabric largely influences the formability of the scaly structure. Thus, if the pile length is large, it is easy to form the apexes of piles into a body with a flat shape and therefore easy to form a scaly structure. On the other hand, if the length is small, it is difficult to form the apexes of pile into a body and the formability of a scaly structure is poor. In view of this fact, 3 mm or more is preferable for the pile length, and 5 mm or more is more preferable. The upper limit of the length of the pile is not especially restricted, but a length of up to about 45 mm is practical from the view point of the manufacturing technology of piled fabrics. The single filament denier of the fibre forming the piled part is not particularly restricted. However, taking formability, durability and aesthetic appearance of the scaly structure into consideration, it is preferable that an ultra-fine artificial fibre whose denier is 1 denier or less, more preferably 0.5 denier or less, is used. Moreover, as the density of numbers of piles of the piled fabric for the raw material, an amount of more than 5,000 piles/cm² is preferable. In particular, the production of a super ultra-fine fibre whose denier is 0.01 denier or less is possible by means of present manufacturing technology of an ultra-fine piled fabric, so that a piled fabric of an ultra-high pile density whose value is 5 to 6 million piles/cm² can be prepared with this super ultra-fine fibre. This piled fabric having such an ultra-high pile density can therefore be used to obtain a three dimensional fabric of the present invention. However, to our knowledge, it is preferable that in general, a high pile density of about 10,000 to 200,000 piles/cm² is used, taking the practical ease or production into consideration. In general, it is desirable that the number of piles per unit area is larger because larger numbers of masses and the condition of a flat shape can be more easily realised in such a case. For these reasons, it is desirable that the above described ultra-fine artificial fibre whose denier is 1 denier or less is used because it can result in an increase in the number of piles. The average value of the area of a constituent unit of the scaly structure is an important factor for obtaining the expected effects of the present invention, especially the effect of the outer appearance having the fashionable characteristics. To our knowledge, it is preferable that the value is in the range of 0.5 x 10⁻² cm² (0.5 mm square) to 1 x 10² cm² (10 cm square) and it is more preferable that it is in the range of 2 x 10⁻² cm² to 1 x 10 cm². For example, for a scaly structure having a small pattern and a relatively smooth feeling, the range of about 0.5 x 10⁻² cm² to 6 x 10⁻² cm² is preferable. On the other hand, for a scaly structure having an intermediate pattern and a relatively bold appearance, the range of about 6 x 10⁻² cm² to 1 x 10 cm² is preferable. Moreover, for a scaly structure having a large pattern and an even bolder appearance, the range of about 1 x 10 cm² to 1 x 10² cm² is preferable. In the present invention, the average value of the area of a constituent unit of the scaly structure V can be obtained by calculating the number of the scaly structures per unit area 100 cm² from the following equation (1) V = 100 cm²/numbers of the scaly structure (1) Where a sampling area of 100 cm² is not adequate, for example, when the pattern is large, a larger sampling area can be properly taken. After all, the average value of the area of a constituent unit should be obtained by dividing the value of the sampling area by the number of the scale structures existing in the area. If the patterns in these area ranges are of a mixture of masses having properly random sizes and properly random shapes without any definite pattern, the appearance overflows with natural feeling and it is aesthetically excellent. If the average value of the area of a constituent unit of the scaly structure is 0.5 x 10⁻² cm² or less, the merit of the existence of the scaly structure decreases and the surface appearance is no different from an ordinary simple piled fabric and lacks uniqueness. On the other hand, if the value exceeds 1 x 10² cm², the whole surface state is flat, resembles a film sheet, and lacks a cubic effect and the touch is papery. It is not desirable in general. However, in an application field such as wall decorative material and so on wherein a material of large size is generally used, such a large pattern of the scaly structure as one exceeding 1 x 10² cm² can be used. After all, the appropriate size changes in accordance with various practical applications. As a raw material constituting the fabric of the present invention, either a natural fibre or a synthetic fibre can be used and a properly blended one can also be used. However, as a fibre forming the piled parts, a heat fusing fibre is preferable, and a synthetic fibre is especially preferable. Examples of the raw material for the synthetic fibres which are preferably used are polyethylene terephthalate or its copolymer (for example, a copolymerizable component such as 5-sodium sulfoisophthalic acid), polybutylene terephthalate or its copolymer, polyamides such as nylon 66, nylon 6 and nylon 12 and polyacrylonitrile type polymers. Polymer compositions wherein modifiers and additives are blended with these polymers for the purposes of destaticizing, improving dyeability, delustering, stain-proofing, fire retarding and shrink-proofing, can also be used. The most practical method for carrying out a press treatment under heating and compression on a pile layer of a piled fabric, adhering a surface layer of the piles formed with apexes of the piles over a wide area and making it into a body with a film-like state, is that in which the pile layer is pressed by means of heated calender rolls and heat treatment is carried out while the pile layer is being compressed. As an alternative to the calender roll method, a compression treatment using a heated plate can be used. When a roll or a plate is used for pressing, the face of the press may be either flat or uneven. In a method embodying the present invention, pressing is generally carried out by means of a press surface with a mirror surface, but an embossing roll or an embossing plate having an embossing pattern of a regular shape or an irregular shape can be used for pressing. By doing so, a three dimensional fabric having the three dimensional pattern with an embossed pattern and being especially fashionable is obtained. A scaly structure can be effectively formed by means of the above described process, but to improve the shape retaining property and durability of the formed scaly structure, a method for fixing the scaly structure with a resin is preferably used. To fix the scaly structure using the resin, the resin is first adhered at least to the surface layer in which the fiber apexes are united, and thereafter crumpling treatment is carried out in order to split the united layer into units of small area and so form the scaly structure. In another process order, a number of scaly structures are formed at first by carrying out a crumpling treatment and then the resin is adhered at least to the parts of the scaly structures. As regards touch, a more flexible and soft product can be obtained by the former process order, but the latter process order is superior to the former for improved durability and shape retaining property. Resins used in this process are acrylic, melamine, vinyl acetate and epoxy resins, their copolymer resins, and high polymer elastomers such as butadiene copolymers, vinyl chloride copolymers and polyurethane. As the method for adding the resin, a process comprising impregnation with the resin squeezing drying curing, and coating methods such as direct transferring, gravure, spraying and so on are preferably used, but it is not especially restricted and is properly selected in accordance with the touch and other characteristics desired. The heating temperature in the calender roll treatment on a pile layer of a piled fabric should be properly selected in accordance with a raw material of the piled fibre, but in general a range of 120 to 230°C is preferable and a range of 160 to 210°C is more preferable. Namely, it is preferable that the treatment is carried out at the temperature wherein the piled fibre reaches a semimolten state. It is therefore difficult to form a scaly structure at too low a temperature condition. On the other hand, at too high a temperature condition, there is a possibility that the physical properties and dyeing fastness of the fabric will decrease. Therefore the above described temperature range, 120 to 230°C, is the most appropriate temperature. Five kg/cm² or more is preferable for the treating pressure of the compression press, and 20 kg/cm² or more is more preferable. Below 5 kg/cm², the pressing pressure is too low and scaly structure formation and durability of the formed pattern are insufficient. Usually, treatment is carried out at a pressure in a range of 20 to 100 kg/cm². When a heat calender roll machine is used as a means of heat compression press treatment, the calender roll machine generally has a three roll structure in which the central cylinder roll is heated and the upper and the lower two plastorolls cannot be heated. It is therefore important that the piled part is contacted with the surfaces of heated cylinder rolls and thereby heat treated. As the treating speed, 0.5 to 20 m/min is preferable in accordance with the kind of machine, and 2 to 10 m/min is more preferable. Above 20 m/min, the fusing effect is poor and the desired adhesion of a mass of apexes of piles to form a body with a flat shape is difficult to achieve and therefore a scaly structure is difficult to form. Durability of shape of the scaly structure is also insufficient. Formation of the scaly structure is largely influenced by the pile condition and the treating direction of a lie of piles of the fabric before heat press treatment. Thus, to obtain a product whose average area of a constituent unit of the scaly structure is 0.5 x 10⁻² cm² to 6 x 10⁻² cm², in other words one in which the scales are small and whose shapes are relatively uniform, handling and managing of the piles are improved in advance for example, by means of brushing and treatment with a finishing agent such as silicones. After such treatment, the pile fibres may lie at an angle to the vertical. A treatment under pressure and heating is then performed on the piled fabric to flatten the pile fibre layer somewhat, ie further, and in the same direction away from, the vertical, the treatment being carried out at a relatively lower temperature (at around 180°C if the raw material of the piles is polyethylene terephthalate). On the other hand, to obtain a product whose average area of a constituent unit of the scaly structure is 6 x 10⁻² cm² or more and which has a surface condition providing an intermediate or large pattern, it is desirable on the contrary that a material wherein handling and managing of the piles has not been improved, so that the piles are in a poor condition, be treated by means of a press and heat treatment to make the fibres assume an angle to the vertical in a direction opposite to that which they assume before application of pressure, hereinafter to referred to as the "reverse direction", and so flatten the pile fibre layer, at a higher temperature (at around 200°C if the raw material of the piles is polyethylene terephthalate). Moreover, to obtain a product wherein various small, intermediate and large patterns exist in a mixed state and whose average area of a constituent unit is in a range of 10⁻² cm² to 10² cm², such a product can be easily obtained by treatment to crumple a product obtained in the above described latter condition, by hand or mechanically. To carry out a mechanical crumpling treatment, one can utilize various apparatus capable of imparting a crumpling action to a fabric. Thus, even those apparatuses that are not manufactured specifically for the purpose of carrying out crumpling treatments, can be utilized. For example, apparatus for softening fabrics (so called vibraker), liquid bath treating apparatus such as in a wince dyeing machine, a liquid flow dyeing machine, a tumble apparatus which physically lifts up and drops a fabric, a beating apparatus which hits a fabric with a bar and a guiding apparatus constituting plural bars for running a fabric in a curved way, can be properly utilized. Moreover, to obtain the three dimensional fabric of the present invention having a substantial number of scaly structures of a fixed pattern, it is possible to use a splitting technique such as rubbing and splitting to make an optional single shape or mixed shapes such as triangles, rectangles, polygons, circles, ellipses and so on and/or optional sizes of these shapes, by using a knife with an edge and so on. In the preceding or the following process for making a scaly structure of the three dimensional fabric of the present invention, additional treatment steps are suitably carried out, for example, a coating treatment applied to the back surface, desizing-scouring and heat setting treatment, treatment of composite fibres to produce ultra-fine fibres (in a case where an artificial fibre capable of producing ultra-fine fibres is used), dyeing, sizing, and drying in the same way as ordinary piled woven and knitted fabrics. However, in the case of the conventional ordinary piled fabrics, a backing treatment is generally done on the back surface of the fabric with a resin coating in many cases to prevent falling out of piles, but in the fabric of the present invention, the problem of piles falling out hardly occurs because the surface layer of the fabric is constituted by a scaly structure. The backing treatment is therefore not necessarily needed. Moreover, water repelling treatment, flame retarding treatment, stain resistant treatment and so on may be suitable done, if necessary, on the three dimensional fabric of the present invention. The present invention will be more specifically explained by the following examples. Example 1 The following two types of islands-in-a-sea type composite fibres were spun and drawn to obtain blended composite fibres of 73 denier - 18 filaments. a) The islands-in-a-sea type composite fibre No. 1 Island component: Polyethylene terephthalate (16 islands) Sea component: Polystyrene b) The islands-in-a-sea type composite fibre No. 2 Island component: Polyethylene terephthalate copolymerized with 10 mole % of isophthalic acid (16 islands) Sea component: Polystyrene Here, the island-in-a-sea type composite fibre No. 1 comprised 80% of the island component and 20% of the sea component, and the whole fibre was 36.5 denier - 9 filaments. The island-in-a-sea type composite fibre No. 2 comprised 80% of the island component and 20% of the sea component, and the whole fibre was 36.5 denier - 9 filaments. Therefore, a blended fibre of total 73 denier - 18 filaments was obtained. This blended composite fibre was used as a pilable fibre. A two folded yarn comprising 30 denier - 12 filaments of polyethylene terephthalate (a twist-set product whose first twist (S direction) was 900 T/m and second twist (Z direction was 900 T/m) was used as a warp of the base fabric, and a false-twist-modified textured yarn of 150 denier - 48 filaments treated with an added twist of 400 T/m (S direction) and set with a twist-set was used as a weft of the base fabric. A fabric whose pile length was 10 mm was obtained by means of a double velludo weaving machine. As the fabric density, piled yarn, base fabric warp and base fabric weft were 46, 91 and 93 yarns/inch. Dry heat setting of the fabric thus obtained was carried out and the sea component of the piled composite yarn was removed by treating with trichlcroethylene to obtain a piled fabric wherein a number of ultra-fine fibres, whose monofilament denier was 0.2 denier, were piled. After drying to remove trichlorcethylene, the back surface of the said fabric was coated with a solution comprising 100 parts of polyurethane, 25 parts of DMF and 0.25 parts of a pigment by means of a knife coater machine. The backing treatment of the back surface of the fabric was thereby carried out. The coating quantity of polyurethane on the fabric was 14.8 g/m². It was thereafter placed into a liquid-flowing circular dyeing machine to angle the piles in a reverse direction, and the dyeing treatments was carried out under the following conditions. (1) Scouring (the treating time: 80°C x 30 min) The treating agents: "Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltd.) 0.5 g/lit. Soda ash 0.5 g/lit. (2) Dyeing (the treating time: 120°C x 60 min) Dyes: Kayalon Polyester Light Red BS 0.5% owf Resoline Blue BBLS 3.0% owf Samalon Black BBL Liq 150 20.0% owf LAP-50 0.5 g/lit. PH-500 0.5 g/lit. (3) Reduction cleaning (the treating time: 80°C x 20 min) The treating agents: NaOH (30%) 3 g/lit. Hydrosulphite 3 g/lit. Sandet G-29 3 g/lit. After dyeing, dehydration was carried out by means of a centrifugal dehydrater. Then, calender treatments under the following conditions (A) and (B) were carried out by means of a hydraulic three-roll plastocalender machine. (A) (B) Temperature (°C) 180 200 Pressure (kg/cm²) 15 80 Treating speed (m/min) 8 8 Pile opening state of the treated fabric Sufficient A little insufficient Direction of the fabric put in the calender Following Reverse During the treatment, the piled part of the fabric was made to contact the heated cylinder roll of the calender roll. Regarding the fabric treated under the condition (A), its pile opening and handling conditions were made good by brushing before the calender treatment. Treated fabrics thus obtained had a layer of apexes of piles adhered over a wide area to form a film-like body. This treated fabric was subjected to a crumpling treatment by passing it through an apparatus for guiding fabric wherein plural bars were placed alternately at a higher and a lower position to make possible a zigzag curved running of the fabric. The fabrics thus obtained by both treatment levels (A) and (B) had apexes of piles in a body with a flat configuration and scaly structures. The area of a constituent unit of the scaly structure produced by treatment (A) was 20 x 10⁻² cm² on the average and had a relatively uniform shape having a relatively small area in the range of 3 x 10⁻² cm² to 36 x 10⁻² cm². The area of the scales produced by treatment (B) was 1.5 x 10 cm² on average and had various shapes and areas, including small as well as large ones in the range of 25 x 10⁻² to 0.8 x 10² cm². All outer appearances were unique and rich in a natural feeling like a bagworm, coal or a skin of a pine tree and rich in lustre characteristic, flexibility and cubic effect. The fabric was rich in aesthetic and high class feelings which had never been seen before. In comparing treatment (A) with treatment (B), it was found that treatment (A) gave a mild feeling because each scaly structure was small, while treatment (B) gave a bold feeling and a feeling full of rural beauty because each scaly structure was large. Example 2 As a piled yarn, a filament yarn of 75 denier-18 filaments obtained by spinning and drawing islands-in-a-sea type composite fibres having the following constitution was used. Island component: Polyethylene terephthalate Sea component: Polystyrene Number of the island component: 6 Ratio of the island/the sea component: 80/20 Monofilament denier of the island component: 0.56 denier A false-twisted textured yarn of polyethylene terephthalate of 75D-36f as a warp of the base fabric and a false-twisted textured yarn of the same polymer of 150D-48f as a weft of the base fabric were used to obtain a fabric having piles whose length was 11 mm by means of a double velludo weaving machine. Regarding the fabric density, the piled yarn, base fabric warp and base fabric weft were 47, 93 and 94 yarns/inch, respectively. After dry heat setting of the piled fabric, the sea component of the composite yarns used for piled yarns was removed by treating with trichloroethylene to obtain a piled fabric wherein a number of ultra-fine fibres whose monofilament denier was 0.56 denier. After drying to remove the trichloroethylene, the back surface of the fabric was coated with a solution comprising 100 parts of polyurethane, 13/18 parts of MEK/toluene, 50/5 parts of water/MEK, 2 parts of a crosslinking agent and 0.25 parts of a pigment by means of a knife coater machine. The backing treatment of the back surface of the piled fabric was thereby carried out. The coating quantity of polyurethane on the fabric was 22 g/m². It was thereafter placed into a liquid-flowing circular dyeing machine to angle the piles in a reverse direction during the dyeing treatment and the dyeing treatment was carried out under the following conditions. (1) Scouring (the treating time: 80°C x 30 min (1) Scouring (the treating time: 80°C x 30 min The treating agents: "Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltd.) 0.5 g/lit. Soda Ash 0.5 g/lit. (2) Dyeing (the treating time: 120°C x 60 min) Dyes: Resoline Blue BBLS 2.5% owf Kayalon Polyester Light Red BS 3.0% owf Foron Yellow Brown S-2RFL 4.6% owf Palanil Yellow 3G 1.7% owf LAP-50 (manufactured by Sanyo Chemical Industries, Co., Ltd.) 0.5 g/lit. PH-500 (manufactured by Sanyo Chemical industries, Co., Ltd.) 0.5 g/lit. (3) Reduction cleaning (the treating time: 80°C x 20 min) The treating agents: NaOH (30%) 3 g/lit. Hydrosulphite 3 g/lit. "Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltd.) 3 g/lit. After dyeing, dehydration was carried out by means of a centrifugal dehydrater. Then, a calender treatment was carried out by means of a hydraulic three-roll plastocalender machine. The treating conditions were as follows. Temperature: 200°C (The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm² Treating speed: 8 m/min Pile opening state of the treated fabric: A little insufficient Direction of the fabric put in the calender: Reverse After the treatment, some crumpling by hand was effected, and a resin treatment was then carried out under the following conditions to obtain a dimensional durability. Resin treatment: Resin impregnation (Pick up 57%) Drying (100°C x 5 min) Curing (180°C x 1 min) Resin composition: "Sumitex Resin M-3 (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 20 g/lit. CB-01 (Cosmo Chemical Co., Ltd.) 2 g/lit. Ammonium Persulphate 2 g/lit. Resin built-up: 0.9% Moreover, the fabric was placed in a Wince dyeing machine containing warm water at 80°C, rotated and moved in the warm water for 20 minutes to crumple it and dried. Treated fabrics thus obtained had apexes of piles in a body and good scaly structures. The average area of a constituent unit of the scaly structures was 2.4 x 10 cm², and the fabric had various large, intermediate and small shapes and areas in the range of 9 x 10⁻² cm² to 0.8 x 10² cm², and the outer appearance exhibited an excellent scaly structure. An excellent fabric having an outer appearance like mica and being rich in a natural feeling, a new, raw material feeling and a fashionable characteristic was obtained. Moreover, durability of the scaly structure was evaluated. The methods for testing durability and the results were as follows. Moreover, comparison tests on an untreated product without any shape fixing treatment by means of resin treatment were carried out. Fixed product Untreated product Test 1 o to o Test 2 o to o x to Test 3 o to o Evaluation level o : No change in shape after the test o : Little change in shape after the test : A little change in shape after the test x : Remarkable change in shape after the test Testing method Test 1: Wearing durability test of an outer coat on both the circumference parts of the elbows and parts of axillae to which a fabric to be tested was attached was carried out for one week. Test 2: Durability test against dry cleanings by means of an ordinary method using perchlene were carried out twice in a dry cleaning shop. Test 3: Abrasion durability test wherein an abrasive go and back cycle test of 50 times was carried out on a surface to be abraded under a pressing load of 500 g by means of Gakushin type abrasion tester. It is clear from Table 1 that the products whose scaly structure was formed by a method including the use of a resin had better durability. Moreover, the products adhered with the resin exhibited an excellent lustre characteristic. The products without resin adherence showed softer feeling and touch but it is recognized that the products with resin adherence also had sufficiently good flexibility. Example 3 The following two kinds of island-in-a-sea type composite fibres were spun and drawn to obtain blended composite fibres of 65 denier - 18 filaments. a) The islands-in-a-sea type composite fibre No.1 Island component: Polyethylene terephthalate (16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid/5-sodium sulfoisophthalic acid/87.5 (70/30)/12.5 mole % b) The islands-in-a-sea type composite fibre No.2 Island component: Polyethylene terephthalate copolymerized with 4.9 mole % of isophthalic acid (16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid/5-sodium sulfoisophthalic acid/87.5 (70/30)/12.5 mole % Here, the islands-in-a-sea type composite fibre No.1 comprised 90% of the island component and 10% of the sea component and the whole fibre was 32.5 denier - 9 filaments. The island-in-a-sea type composite fibre No.2 comprised 90% of the island component and 10% of the sea component and the whole fibre was 32.5 denier - 9 filaments. Therefore, a blended fibre of total 65 denier - 18 filaments was obtained. This blended composite fibre was used as a pilable fibre. A false-twisted textured yarn comprising 75 denier - 36 filaments of polyethylene terephthalate was used as a warp of the base fabric, and a false twisted textured yarn of 100 denier - 48 filaments of polyethylene terephthalate was used as a weft of the base fabric. A fabric whose pile length was 6 mm was obtained by means of a double velludo weaving machine. Regarding fabric density, the piled yarn, base fabric warp and base fabric weft were 45.5, 91 and 107 yarns/inch. After dry heat setting of the fabric thus obtained was carried out, the following treatment was carried out by means of a liquid-flowing circular dyeing machine. (1) Treatment for preparing an ultra-fine fibre The 1st treatment: Treating agent: Malechead CM (manufactured by Takeda Chemicals Industry Co., Ltd.) 1 g/lit. Treating temperature x time: 120°C x 30 mins The 2nd treatment: Treating agent: NaOH (30%) 3 g/lit. Treating temperature x time: 80°C x 30 mins (2) Dyeing Dyes: Resoline Blue BBLS 0.53% owf Kayalon Polyester Light Red BS 0.73% owf Foron Yellow Brown S-2RFL 3.2% owf (3) Reduction cleaning The treating agents: NaOH (30%) 3 g/lit. Hydrosulphite 3 g/lit. Sandet G-29 1 g/lit. (4) Silicone treatment Treating agent: Ultratex ESC (manufactured by CIBA-GEIGY) 0.3% owf Treating temperature x time: 20°C x 10 minutes An ultra-fine piled fabric whose monofilament denier was 0.2 denier was obtained by these treatments. After drying the ultra-fine piled fabric, a calender treatment using the conditions described below was carried out by means of a hydraulic three-roll plastocalender machine. The treating conditions were as follows. Temperature: 190°C (The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm² Treating speed: 8 m/min Pile opening state of the treated fabric: A little insufficient Direction of the fabric placed in the calender: Reverse A resin treatment under the following conditions was immediately carried out on the calender treated fabric thus obtained. Resin treatment process: Resin impregnation (Pick up 41%) Drying (100°C x 5 min) Curing (120°C x 3 min) Resin composition: "Sumitex Resin M-3" (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 28 g/lit. CB-01 (Cosmo Chemical Co., Ltd.) 2 g/lit. Ammonium Persulphate 2 g/lit. Resin built-up: 0.3% Moreover, the fabric was placed in a liquid-flowing circular dyeing machine and the fabric was circulated in the liquid-flowing circular dyeing machine for 12 minutes to carry out a crumpling treatment. The bath ratio was 1:30, and the nozzle pressure was 1.2 kg/cm². The three dimensional fabric of the present invention thus obtained had a scaly structure whose constituent unit was in the range of 1 x 10⁻² cm² to 5 x 10⁻² cm² and relatively small and whose size was relatively uniform. This three dimensional fabric had a number of small scaly structures densely covering its surface, and the outer appearance was beautiful with these scaly structures. The fabric exhibited a mild feeling and was rich in a natural feeling, a new, raw material feeling and a fashionable characteristic. The three dimensional fabric of Example 3 was different from those of Examples 1 and 2 because the piled fabric had no backing treatment with a resin. The touch of the fabric was therefore very soft and the fabric was good for apparel use having excellent drapery. The three dimensional fabric having a unique structure of the present invention can be widely used in such various applications for which fashion characteristics are important by utilizing its new, raw material feeling and unexpected feeling. Thus, it can be used for fashionable outer wears, for example, outer garments such as overcoats, raincoats, capes and shawls, jackets such as sports jackets, suits and business suits, trousers such as slacks and pants, and outer wears such as hats and gloves. It can be also used for a surface raw material for bags rich in a fashionable feeling, for example, handbags, various briefcases and various suitcases. Moreover, it can also be used for wall decorative materials such as inner and outer wall materials being rich in a new feeling and a new, raw material feeling. Furthermore, it can also be used for interior materials such as curtains, floor materials, carpets, chair cloths, cases for exhibiting goods and tent materials for shop canopies. Finally, it can also be used for shoes and boots.

Claims: A three dimensional fabric (1) comprising a base fabric (5) and pile fibres (3) projecting from the base fabric (5), apexes of which pile fibres together define a pile surface (2) characterized in that, in respective adjacent regions of the pile surface, the apexes of the pile fibres are joined together in side-by-side relationship to provide respective substantially continuous surface parts (4) which said substantially continuous surface parts are at least partly separate from one another, whereby the pile surface comprises a plurality of adjacent said surface parts. A three dimensional fabric according to claim 1, wherein the said surface parts (4) have respective shapes which together provide substantially no definite pattern on the said pile surface (2). A three dimensional fabric according to claim 1 or claim 2, wherein the average area of each said surface part (4) is 0.5 x 10⁻² cm² to 1 x 10⁻² cm². A three dimensional fabric according to any preceding claim wherein at least some of the said surface parts (4) have a peripheral boundary region (9) so disposed as to reveal splits therebetween, thereby providing a fibrous appearance at the boundary regions at least on flexing of the fabric. A three dimensional fabric according to any preceding claim, wherein a number of the apexes of the pile fibres defining the said surface parts (4) are joined together with a resin. A method for preparing a three dimensional fabric (1) having a surface of scale-like appearance, which method comprises providing a fabric structure comprising a base fabric (5) and pile fibres (3) projecting from the base fabric (5) to define a pile surface (2) subjecting the fabric structure to a heat and compression treatment, optionally in the presence of an adhesive, so as to join together, in side-by-side relationship, apexes of adjacent said pile fibres to form, at the said pile surface, a substantially continuous film defined by the said apexes and subjecting the fabric structure to a crumpling operation so as to break the said film and thereby provide substantially continuous parts (4) of the pile surface (2) which parts are at least partly separate from one another, whereby the three dimensional fabric (1) has the scale-like appearance. A method according to claim 6, wherein the heat and compression treatment is carried out using calender rolls. A method according to claim 6 or claim 7, wherein the heat and compression treatment is carried out in the presence of an adhesive resin. A method according to any one of claims 6 to 8, wherein an adhesive resin is applied to at least a part of the pile surface (2) before the crumpling treatment. A method according to any one of claims 6 to 9, wherein the pile fibres (3) are ultra-fine synthetic fibres. A method according to claim 10, wherein the ultra-fine synthetic fibres have a monofilament denier of 1 denier or less. A method according to Claim 11, wherein the ultra-fine synthetic fibres have a monofilament denier of 0.5 denier or less.

Inventors: NAKAJIMA, TAMOTU, YOSHIDA, SHUSUKE
Applicants: TORAY INDUSTRIES, INC.
Application year: 1988
Main classification: D03D27
IPC codes: D06N7, D06C27, D03D27, D06Q1