Pile fabric production process

• US 4,574,018 A
• Filed: 12/30/1983
• Issued: 03/04/1986
• Est. Priority Date: 01/07/1983
• Status: Expired due to Fees

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Nakamura, Teruo, Masuda, Yutaka
• Primary Examiner(s): Ball, Michael
• Application Number:
  US06/567,265
• Time in Patent Office: 795 Days
• Field of Search: 156/155, 156/168, 156/72, 156/344, 156/283, 156/83, 428/91, 428/90, 428/95, 427/26, 427/206, 427/352
• US Class Current: 156/72
• CPC Class Codes: D04H 11/00 Non-woven pile fabrics layered products forming non-woven pile fabrics B32B
• CPC Class Codes: Y10T 428/23943 Flock surface
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition

Abstract

Pile fabric having excellent softness and high tear strength which has short fibers planted and adhered to a base with an adhesive, is obtained by applying an adhesive and planting the short fibers to the base, drying or curing the adhesive, and removing at least 5 weight % of the fibers of the base.

Claims

1. A process for producing a pile fabric which comprises providing a fiber base composed of composite fibers, which fibers comprise at least two individual components, applying an adhesive to said fiber base, electrostatically implanting short flock fibers in said adhesive and fiber base, hardening said adhesive with said short fibers in place, and thereafter removing at least one component of the fiber base.

2. A process according to claim 1, wherein the fiber of the base includes a polyester as one of said components and the removal is effected by alkali treatment.

3. A process according to claim 1, wherein the fiber of the base is a sheath-core type composite fiber.

4. A process according to claim 3, wherein the fiber of the base is an islands-in-sea type composite fiber.

5. A process according to claim 1, wherein the short fibers are composed of at least two different fibers differing in thickness and length.

6. A process according to claim 5, wherein at least the thicker fibers are both end tapered fibers.

7. A process according to claim 1, wherein hardening of the adhesive is developed by drying.

8. A process according to claim 1, wherein hardening of the adhesive is developed by curing.

9. A process according to claim 1, wherein removal is effected by treatment with solvent.

10. A process according to claim 1, wherein removal is effected by decomposition.