Pile fabric and method for manufacturing same

Abstract

A pile fabric includes ground yarns constituting a ground structure; pile fibers that are tangled with the ground yarns, the pile fibers including portions standing on a front surface side of the ground structure; and an organically-modified silicone-based softener adhered to the pile fibers located on a back surface side of the pile fabric. The pile fibers include at least one selected from the group consisting of acrylic fibers and modacrylic fibers, and have a softening point lower than a softening point of the ground yarns. The portions standing on the front surface side of the ground structure are not fused to each other, and on a back surface side of the ground structure, at least part of the pile fibers located outside of the ground yarns are fused to each other.

What is claimed is: 
     
         1 . A pile fabric, comprising:
 ground yarns constituting a ground structure;   pile fibers that are tangled with the ground yarns, the pile fibers comprising portions standing on a front surface side of the ground structure; and   an organically-modified silicone-based softener adhered to the pile fibers located on a back surface side of the pile fabric,   wherein the pile fibers comprise at least one selected from the group consisting of acrylic fibers and modacrylic fibers, and have a softening point lower than a softening point of the ground yarns,   wherein the portions standing on the front surface side of the ground structure are not fused to each other, and on a back surface side of the ground structure, at least part of the pile fibers located outside of the ground yarns are fused to each other,   wherein an amount of the organically-modified silicone-based softener is 0.4 parts by weight or more with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric, and   wherein the organically-modified silicone-based softener is at least one selected from the group consisting of amino-modified silicone-based softeners, epoxy-modified silicone-based softeners, and carboxyl-modified silicone-based softeners.   
     
     
         2 . The pile fabric according to  claim 1 , wherein the organically-modified silicone-based softener is an amino-modified silicone-based softener. 
     
     
         3 . The pile fabric according to  claim 1 , wherein the pile fibers are modacrylic fibers. 
     
     
         4 . The pile fabric according to  claim 2 , wherein the pile fibers are modacrylic fibers. 
     
     
         5 . The pile fabric according to  claim 1 , wherein the ground yarns are polyester fiber yarns. 
     
     
         6 . The pile fabric according to  claim 2 , wherein the ground yarns are polyester fiber yarns. 
     
     
         7 . The pile fabric according to  claim 3 , wherein the ground yarns are polyester fiber yarns. 
     
     
         8 . The pile fabric according to  claim 1 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric. 
     
     
         9 . The pile fabric according to  claim 2 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric. 
     
     
         10 . The pile fabric according to  claim 3 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric. 
     
     
         11 . A method for producing a pile fabric, comprising:
 preparing a pile fabric, wherein the pile fabric comprises ground yarns constituting a ground structure and pile fibers that are tangled with the ground yarns, the pile fibers comprising portions standing on a front surface side of the ground structure;   attaching an organically-modified silicone-based softener to the pile fibers located on a back surface side of the pile fabric; and   heat sealing the back surface side of the pile fabric at a temperature that is equal to or higher than a softening point of the pile fibers and lower than a softening point of the ground yarns,   wherein the pile fibers comprise at least one selected from the group consisting of acrylic fibers and modacrylic fibers, and have a softening point lower than a softening point of the ground yarns,   wherein an amount of the organically-modified silicone-based softener is 0.4 parts by weight or more with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric,   wherein the organically-modified silicone-based softener is at least one selected from the group consisting of amino-modified silicone-based softeners, epoxy-modified silicone-based softeners, and carboxyl-modified silicone-based softeners, and   wherein the portions of the pile fibers standing on the front surface side of the ground structure are not fused to each other, and on a back surface side of the ground structure, at least part of the pile fibers located outside of the ground yarns are fused to each other after the heat sealing.   
     
     
         12 . The method for producing a pile fabric according to  claim 11 , wherein the organically-modified silicone-based softener is an amino-modified silicone-based softener. 
     
     
         13 . The method for producing a pile fabric according to  claim 11 , wherein the pile fibers are modacrylic fibers. 
     
     
         14 . The method for producing a pile fabric according to  claim 12 , wherein the pile fibers are modacrylic fibers. 
     
     
         15 . The method for producing a pile fabric according to  claim 11 , wherein the ground yarns are polyester fiber yarns. 
     
     
         16 . The method for producing a pile fabric according to  claim 12 , wherein the ground yarns are polyester fiber yarns. 
     
     
         17 . The method for producing a pile fabric according to  claim 13 , wherein the ground yarns are polyester fiber yarns. 
     
     
         18 . The method for producing a pile fabric according to  claim 11 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric. 
     
     
         19 . The method for producing a pile fabric according to  claim 12 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric. 
     
     
         20 . The method for producing a pile fabric according to  claim 13 , wherein the amount of the organically-modified silicone-based softener is 0.4 to 2.5 parts by weight with respect to 100 parts by weight of the pile fibers located on the back surface side of the pile fabric.