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Pile fabric and method for producing the sameRelated Patent Categories: Stock Material Or Miscellaneous Articles, Pile Or Nap Type Surface Or ComponentPile fabric and method for producing the same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070122585, Pile fabric and method for producing the same. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The present invention relates to a pile fabric composed of a ground structure portion and a cut pile portion, and to a method for producing the same. In more detail, the present invention relates to a pile fabric having moderately inclined portions on the surface of the cut pile portion and giving a rich high grade sense, and to a method for producing the same. BACKGROUND ART [0002] Hitherto, pile fabrics have been used in the fields of vehicle interior materials, interior materials, clothes and the like as central fields. In recent years, pile fabrics having three-dimensional patterns on their surfaces among such the pile fabrics have been noted as pile fabrics giving rich high grade senses. As. methods for forming such the three-dimensional patterns, methods for physically forming concaves and convexes and methods for chemically forming the concaves and the convexes have been known. [0003] As the method for physically forming the concaves and the convexes, a method for embossing by the contact pressure of a sculptured roll under heating at a high temperature (for example, embossing processing, Schreiner processing) has been known, but there have been a problem that the hardening of a hand and the flattening of the fabric are highly enlarged, because the fabric is inserted between heating rolls under a heavy load, and a problem that metallic luster is developed with the heating rolls to cause a thermal discoloration. [0004] On the other hand, as the methods for chemically forming the concaves and the convexes, a method for printing an alkali agent consisting mainly of sodium hydroxide and dissolving the printed portions to form a concave-convex difference (a step-wise difference' in level) (for example, see Patent document 1), or a method for spraying an inorganic or organic solvent as a fiber-shrinking agent on a pile fabric to shrink cut piles, thereby forming the deep sharp uneven pattern (for example, see Patent document 2) have been proposed. However, it could not have been said that the pile fabric having the stepwise concave-convex difference and the pile fabric having the deep sharp uneven pattern are satisfactory at the point of the high grade sense. In addition, the method for spraying the fiber-shrinking agent on the pile fabric has had a problem that a nozzle portion is clogged and a problem that a computer-controlled special spraying device is needed, because the fiber-shrinking agent is usually highly viscous. [0005] [Patent document 1]: JP-B 2-35075 (JP-B means "Japanese Examined Patent Publication"). [0006] [Patent document 2]: JP-A 10-298863 (JP-A means "Japanese Unexamined Patent Publication") DISCLOSURE OF INVENTION [0007] The object of the present invention is to provide a pile fabric giving a rich high grade sense and a method for producing the same. The above-mentioned object can be achieved by the pile fabric of the present invention and the method for producing the same. [0008] The pile fabric of the present invention is a pile fabric composed of a ground structure portion having a knitted or woven structure comprising organic fiber yarns and a cut pile portion comprising polyester-based yarns, characterized in that the height of the cut pile portion is gradually reduced to form inclined portions having inclination angles of 0.5 to 10 degree, respectively, in one or more partial regions of the above-mentioned cut pile portion. [0009] Herein, it is preferable that two or more kinds of cut piles having mutually different brightness and/or mutually different hues, respectively, are contained in the above-mentioned cut pile portion to gradually change the color along the slopes of the inclined portions. [0010] Also, it is preferable that a depth difference between the maximum cut pile portion height and the minimum cut pile portion height in each of the above-mentioned inclined portions is in a range of 0.6 to 1.0 mm. [0011] Also, its is preferable that a plurality of the inclined portions are formed in the cut pile portion and a pattern is formed with a plurality of the inclined portions. [0012] In the pile fabric of the present invention, it is preferable that the number of fine concaves having areas of not less than 0.05 mm.sup.2, respectively, is not more than 120 fine concaves/cm.sup.2 in the maximum cut pile portion height side 40% region of each of the above-mentioned inclined portions. [0013] Further, it is preferable that the total area of the fine concaves having areas of not less than 0.05 mm.sup.2, respectively, in the maximum cut pile portion height side 40% region is not more than 20% based on the total area of the above-mentioned 40% region. [0014] It is preferable that color printing is applied to the pile fabric of the present invention. [0015] The pile fabric of the present invention can be obtained by a method for producing the pile fabric, characterized by partially removing the cut pile portion of the pile fabric composed of a ground structure portion having a knitted or woven structure comprising organic fiber yarns and a cut pile portion comprising polyester-based yarns, by a chemical etching method, to gradually reduce the height of the cut pile portion, thereby forming inclined portions having inclination angles of 0.5 to 10 degree, respectively. [0016] Therein, it is preferable that two or more kinds of cut piles having mutually different cut pile heights, respectively, are contained in the cut pile portion, before the cut pile portion is partially removed by a chemical etching. method, and the cut piles have mutually different brightness and / or mutually different hues, respectively. [0017] Also, it is preferable that a rotary screen having portions where the diameters of etching treating liquid-discharging holes are gradually increased is used, when the cut pile portion is partially removed by the chemical etching method. [0018] Therein, it is preferable that two to five rotary screens are sequentially put on the cut pile portion and used to apply the chemical etching treatment. BRIEF DESCRIPTION OF DRAWINGS [0019] FIG. 1 is an explanatory view for typically showing a state that an inclined portion 1 is formed in the cut pile portion, in the pile fabric of the present invention. [0020] FIG. 2 is an explanatory view for typically showing another embodiment, in the pile fabric of the present invention. [0021] FIG. 3 is an explanatory view for typically showing a state that non-inclined steps are formed in a pile portion, in a conventional pile fabric. [0022] FIG. 4 is an explanatory view for explaining the cut pile portion height L of the cut pile portion, in the pile fabric of the present invention. Continue reading about Pile fabric and method for producing the same... Full patent description for Pile fabric and method for producing the same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Pile fabric and method for producing the same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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