ANTI-PILLING CLOTH AND METHOD FOR MANUFACTURING SAME

Abstract

Provided are: a cloth including thermoplastic synthetic staple fibers, especially a woven or knitted fabric in which occurrence of pilling is suppressed and a reduction of the strength or deterioration of the texture of the cloth is suppressed; and a method for manufacturing the cloth. An anti-pilling cloth including thermoplastic synthetic staple fibers, wherein the anti-pilling cloth is characterized by having, on the surface of at least one side of the cloth, melt balls at ends of the staple fibers and polishing traces of melt balls at fluff tip ends of the staple fibers; and a method for manufacturing the anti-pilling cloth.

Claims

1. An anti-pilling cloth containing thermoplastic synthetic staple fibers, having melt balls on the ends of the staple fibers and polishing traces of the melt balls on the fluff tips of the staple fibers on at least one side of the cloth.

2. The anti-pilling cloth according to claim 1, wherein the thermoplastic synthetic staple fibers are fibers selected from the group consisting of polyester-based, polyamide-based, polyacrylic-based, polyvinyl chloride-based, polyvinylidene chloride-based, polyvinyl alcohol-based, polyolefin-based and polyurethane-based fibers.

3. The anti-pilling cloth according to claim 1 or 2, which is a woven or knitted fabric.

4. The anti-pilling cloth according to claim 3, wherein the anti-pilling grade as determined in accordance with Method A of JIS L1076 (method using an ICI-type tester) after washing 10 times and 30 times in accordance with Method C4M of JIS L1930 (using tumble drying) is grade 3 or higher.

5. A method for manufacturing an anti-pilling cloth comprising the steps of: using filament yarn and/or staple fibers of thermoplastic synthetic fibers as raw yarn and weaving or knitting a cloth having fluff on the cut ends of the filament yarn or fluff on the staple fibers, forming melt balls on the cut ends of the filament yarn or on the ends of the staple fibers by singeing at least one side of the resulting cloth, and forming polishing traces by scraping the melt balls on the cut ends of the filament yarn or on the fluff tips of the staple fibers formed on the thermoplastic synthetic fibers by polishing.

6. The method according to claim 5, wherein the thermoplastic synthetic fibers are fibers selected from the group consisting of polyester-based, polyamide-based, polyacrylic-based, polyvinyl chloride-based, polyvinylidene chloride-based, polyvinyl alcohol-based, polyolefin-based and polyurethane-based fibers.

7. The method according to claim 5 or 6, wherein the anti-pilling cloth is a woven or knitted fabric.

8. The method according to claim 7, wherein the anti-pilling grade of the anti-pilling cloth as determined in accordance with Method A of JIS L1076 (method using an ICI-type tester) after washing 10 times and 30 times in accordance with Method C4M of JIS L1930 (using tumble drying) is grade 3 or higher.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0044] FIG. 1 is an electron micrograph of a cloth surface after 10 rounds of washing a spun polyester plain woven finished article (regular processed product) produced in Comparative Example 1.

[0045] FIG. 2 is an electron micrograph of a cloth surface after 30 rounds of washing a spun polyester plain woven finished article (regularly processed product) produced in Comparative Example 1.

[0046] FIG. 3 is an electron micrograph of a cloth surface after 10 rounds of washing a spun polyester plain-woven finished article (singeing+polishing) produced in Example 1.

[0047] FIG. 4 is an electron micrograph of a cloth surface after 30 rounds of washing a spun polyester plain woven finished article (singeing+polishing) produced in Example 1.

[0048] FIG. 5 is an electron micrograph of a cloth surface (singeing only) immediately after having carried out singeing following desizing and scouring of gray fabric at an intermediate stage of the production of a spun polyester plain woven fabric produced in Example 1.

[0049] FIG. 6 is an electron micrograph of a cloth surface immediately after having finished (singeing+polishing) a spun polyester plain woven fabric finished article produced in Example 1.

[0050] FIG. 7 is an electron micrograph of a cloth surface (regular processed product) of a spun polyester plain woven fabric finished article (regular processed product) produced in Comparative Example 3.

[0051] FIG. 8 is an electron micrograph of a cloth surface (singeing only) immediately after having carried out singeing processing after desizing and scouring a spun polyester plain woven fabric finished article produced in Example 2.

[0052] FIG. 9 is an electron micrograph of a cloth surface (singeing only) immediately after having carried out singeing following desizing and scouring of gray fabric at an intermediate stage of the production of a spun polyester plain woven fabric produced in Example 2.

[0053] FIG. 10 is a schematic diagram showing one example of a belt sander apparatus for forming polishing traces by scraping the melt balls on fluff tips following singeing.

DESCRIPTION OF EMBODIMENTS

[0054] The following provides a detailed explanation of embodiments of the present invention.

[0055] One embodiment of the present invention is an anti-pilling cloth containing thermoplastic synthetic staple fibers, having melt balls on the ends of the staple fibers and polishing traces of the melt balls on the fluff tips of the staple fibers on at least one side of the cloth.

[0056] In the present description, the term thermoplastic synthetic fibers refers to chemical fibers comprised of a chemically synthesized polymer, although there are no particular limitations thereon provided melt balls are formed that are obtained by gas singeing and the like, and examples thereof include synthetic fibers such as polyester-based, polyamide-based, polyacrylic-based, polyvinyl chloride-based, polyvinylidene chloride-based, polyvinyl alcohol-based, polyolefin-based or polyurethane-based fibers. For example, the melting point of polyester-based staple fibers is 255 C. to 260 C., the melting point of polyamide-based fibers in the form of nylon staple fibers is 215 C. to 220 C., the softening point of polyacrylic-based fibers is 190 C. to 240 C. although the melting point is not clear, and the melting point of polyolefin-based fibers in the form of polypropylene staple fibers is 165 C. to 173 C. In contrast, natural fibers in the form of cotton (upland) fibers decompose at 235 C. and burn at 275 C. to 456 C., while wool (merino) undergoes thermal decomposition at 130 C., becomes scorched at 205 C. and carbonizes at 300 C. In addition, regenerated cellulose fibers in the form of rayon or cupra fibers do not soften or melt, but rather become colored and begin to decompose at 160 C. to 300 C. The thermoplastic synthetic fibers in the present embodiment are preferably fibers selected from the group consisting of polyester-based, polyamide-based, polyacrylic-based, polyvinyl chloride-based, polyvinylidene chloride-based, polyolefin-based and polyurethane-based fibers, and are more preferably polyester-based, polyamide-based or polyacrylic-based fibers.

[0057] In the present description, the term staple fibers refers to fibers that have been cut to a short length, and in the case the staple fibers are thermoplastic synthetic staple fibers, they are typically fibers obtained by cutting fibers made in the form of filaments. From the viewpoint of spinning processability, the length of the staple fibers is preferably 20 mm to 70 mm, more preferably 30 mm to 60 mm and even more preferably 38 mm to 51 mm. From the viewpoints of spinnability and retaining cloth strength, the fineness (single fiber fineness) of the staple fibers is preferably 0.01 denier to 10 denier, more preferably 0.8 denier to 5 denier and even more preferably 1.0 denier to 2.5 denier. If the single fiber fineness is less than 0.01 denier, there is increased susceptibility to soiling and fluff forms and gathers on the ends resulting in greater susceptibility to the formation of pills, while if the single fiber fineness exceeds 10 denier, although there is less generation of fluff, due to the increase in strength, it becomes difficult to remove pills once they have formed and texture is impaired. The cross-sectional shape of the staple fibers may be circular or irregular.

[0058] Furthermore, in the present description, the term staple fibers also includes fibers having cut ends that have formed as a result of filaments having been cut by weaving, knitting or raising treatment on the surface of gray fabric obtained by weaving or knitting using thermoplastic synthetic filaments as raw yarn.

[0059] In the present description, the term spun yam refers to yarn obtained by unraveling staple fibers, arranging the fibers so as to be combed, twisting and bundling. Although the spun yarn is preferably comprised only of one type of thermoplastic synthetic staple fibers from the viewpoint of melt ball formation, the spun yarn may also be a blended yarn comprised of two or more types of thermoplastic synthetic staple fibers. In addition, the spun yarn may also be a blended yarn comprised of thermoplastic synthetic staple fibers and other natural fibers or may be composite fiber yarn, union yarn twisted with filament yarn, or spun twisted yarn. The yarn count of the spun yarn is preferably 7 to 120 (760 denier to 44 denier). The cloth becomes thick if the yarn count is less than 7, while strength decreases if the yarn count exceeds 120. In addition, the twist count is preferably 60 twists/m to 1500 twists/m.

[0060] In the present description, the term cloth refers to any of a woven fabric, knitted fabric (circular knitted fabric, warp knitted fabric or weft knitted fabric) or nonwoven fabric. The cloth is preferably a woven fabric or knitted fabric from the viewpoint of demonstrating a desired effect as a clothing product. Although the woven fabric is preferably composed of 100% spun yarn, a mixed fabric using filaments for the warp and spun yarn for the weft is preferable since it allows the obtaining of a soft and resilient texture. There are no particular restrictions on the woven structure or knit structure. Moreover, in the present description, the term woven or knitted fabric refers to either a woven fabric or knitted fabric.

[0061] In the present description, the term fluff refers to the ends of staple fibers that have risen from the cloth surface, while the ends of staple fibers present within the cloth or within the composing spun yarn are not referred to as fluff. FIGS. 1 and 2 indicate an example of polyester fluff, while FIG. 7 indicates an example of nylon fluff.

[0062] In the present description, the term melt ball refers to that which is formed into roughly a spherical shape as a result of the fluff of thermoplastic synthetic fibers being melted by singeing. In the present embodiment, melt balls present on the surface of cloth are converted to polishing traces as a result of being scraped by polishing. FIG. 5 indicates an example of polyester melt balls while FIG. 9 indicates an example of nylon melt balls.

[0063] In the present description, the term polishing traces refers to the ends of staple fibers of a shape having traces where melt balls on a cloth surface were scraped by polishing. FIGS. 3, 4 and 6 indicate an example of polyester polishing traces while FIG. 8 indicates an example of nylon polishing traces.

[0064] Another embodiment of the present invention is a method for manufacturing an anti-pilling cloth that includes the steps of:

[0065] using spun yarn containing thermoplastic synthetic staple fibers as raw yarn and weaving or knitting a cloth having fluff on staple fibers,

[0066] forming melt balls on the cut ends of the staple fibers by singeing at least one side of the resulting woven fabric or knitted fabric, and

[0067] forming polishing traces by scraping the melt balls on the cut ends of the fluff tips of the staple fibers formed one side of the resulting woven fabric or knitted fabric by polishing.

[0068] The following provides an explanation of one example of the manufacturing of the anti-pilling cloth of the present embodiment.

[0069] Thermoplastic synthetic staple fibers are spun into spun yarn. At that time, the spun yarn may be a blended yarn of two or more types of thermoplastic synthetic fibers or may be a blended yarn of one or more types of thermoplastic synthetic fibers and one or more types of natural fibers.

[0070] Next, the spun yarn is woven using as warp yarn and/or weft yarn to obtain a gray fabric.

[0071] Next, the gray fabric is subjected to desizing and scouring.

[0072] Next, singeing is carried out in the manner described below.

[0073] (Singeing)

[0074] Melt balls are formed on the tips of fluff present on the cloth surface. At this time, although there are cases in which the melt balls are formed on the ends of staple fibers on the exterior of the spun yam, since melt balls may also be embedded within the cloth and melt balls present at such sites do not appear on the cloth surface, there is no risk of impairing the texture of the cloth. Singeing can be carried out by, for example, direct singeing with the flame of a gas burner (gas singeing) and/or indirect singeing by contact with a heated roller (contact singeing). Since the melting points of polyester and nylon are 210 C. to 260 C., direct singeing is preferable. Indirect singeing, in which heat is transmitted in a short period of time with the temperature of the heated roller at a higher temperature, is preferable for materials having higher melting points. Although there are no particular restrictions on singeing conditions, melt balls should be allowed to form on fluff tips present on the cloth surface that cause the occurrence of pilling. The transit speed of the woven fabric supplied to the singeing step (singeing processing speed) is preferably 60 m/min to 120 m/min and more preferably 80 m/min to 100 m/min. Furthermore, in the case the spun yarn contains natural fibers, gas singeing is preferable since pilling is inhibited if the fluff of natural fibers is carbonized and burned off by gas singeing.

[0075] Next, polishing is carried out in the manner described below.

[0076] (Polishing)

[0077] Melt balls on the fluff tips of staple fibers formed on at least one side of a woven fabric or knitted fabric by singeing as described above are, for example, scraped by polishing using an abrasive or sandpaper to form polishing traces. Polishing is preferably carried out on both sides in the case melt balls are formed on both sides of the cloth. Polishing may be carried out manually or using various types of polishers. Roll polishers in which an abrasive is applied to a roller, roll polishers in which sandpaper is wrapped around a roller, or belt sanders using a sandpaper belt can be used as polishers. FIG. 10 indicates an example of a polishing apparatus that uses a belt sander. In the case of polishing both sides of a cloth using a belt sander, polishing is carried out twice by interchanging the polished side. As shown in FIG. 10, following singeing, the cloth passes over reversing rollers (1 and 2), is preheated with heated cylinders (3 to 5), passes over reversing rollers (6 to 8), and is pressed against a rotating belt sander (10) while adjusting the pressing force with a movable retainer valve (9), thereby scraping off melt balls on the cloth surface resulting in the formation of polishing traces. Powder generated by this polishing is removed with a paper powder remover (11) and cloth powder removers (12 and 14), after which the cloth from which the powder has been removed is finally recovered after being folded over with a shaking device (19).

[0078] Although conventional anti-pilling measures employing polishing consisted of fibrillation as described in PTL5, the polishing in the present embodiment is carried out in order to scrape off melt balls that have formed due to singeing. As shown in FIGS. 5 and 9, since melt balls have a roughly spherical shape of a prescribed size, when scraped off by contacting with an abrasive or sandpaper with a cloth surface, the melt balls are unable to enter inside the cloth, thereby enabling polishing and scraping to be carried out preferentially and minimizing damage to the structure of the woven fabric. Thus, as a result of this polishing, the problems of roughening of the cloth and exacerbation of texture and appearance due to melt balls remaining on the cloth, which had been the major problem associated with singeing of thermoplastic synthetic fibers, are resolved and decreases in cloth strength are inhibited. As was previously described, although PTL4 and PTL5 teach extraordinary polishing methods, these polishing methods are techniques applied to raised products, and since fluff (fluff tips) end up escaping even when polished due to the hard fluff in the case of spun yarn comprised of synthetic fibers, it is difficult to treat only that fluff that causes the occurrence of pilling without damaging the cloth material. However, the inventor of the present invention found that, since it is difficult for fluff to escape if melt balls are formed on the tips thereof by singeing, the melt balls can be polished by scraping without damaging the cloth material and woven fabric can be produced having extremely superior pilling resistance, thereby leading to completion of the present invention. In addition, as was previously described, although PTL3 describes to the effect that melt balls formed by singeing synthetic fibers can be removed by shearing, since shearing is inherently a method for cutting away raised fibers, it is in fact difficult to apply to products other than raised products in the same manner as polishing, and even if it were to be applied, since there is an extremely high risk of damaging the cloth material, in actuality it is not used.

[0079] (Raising Treatment)

[0080] The method for manufacturing an anti-pilling cloth of the present embodiment can also be applied to woven fabric or knitted fabric having a surface subjected to raising treatment. Examples of methods used to form a raised state on the surface of a woven or knitted fabric using spun yarn containing thermoplastic synthetic staple fibers for the raw yarn include processing methods in the manner of card clothing raising treatment and emery raising treatment, methods employing weaving in the manner of pile fabrics, and methods employing knitting in the manner of knitted fabrics obtained by center cutting double Raschel knit fabric. At least one side of a woven fabric or knitted fabric having a surface subjected to raising treatment is singed to form melt balls on the ends of the staple fibers, after which melt balls on the fluff tips of the staple fibers that have formed on one side of the resulting woven fabric or knitted fabric are scraped by polishing to form polishing traces.

[0081] In addition, the method for manufacturing anti-pilling cloth of the present embodiment can also be applied to woven fabric or knitted fabric in which staple fibers are present as a result of cutting filaments by weaving, knitting or raising treatment and the like on the surface of gray fabric that has been woven or knit using filaments of thermoplastic synthetic fibers for the raw yarn. This is because, if fiber ends are present on the surface on one side of a fabric, melt balls are formed on the ends of the fibers due to singeing, and polishing traces can be formed by scraping off the melt balls on the fluff tips formed on one side of the resulting woven fabric or knitted fabric by polishing, thereby making it possible to demonstrate a desired effect.

[0082] (Heat Setting)

[0083] Next, heat treatment is carried out to eliminate the effects of uneven thermal hysteresis of synthetic fibers. It is preferable to carry out heat setting in order to achieve dimensional stability and uniform dyeing of a woven fabric. In the case of polyester fibers or nylon fibers, heat treatment is carried out for about 30 seconds to 1 minute at 180 C.

[0084] (Dyeing)

[0085] There are no particular limitations on dyeing. Dyeing includes squeeze dyeing and continuous dyeing, and squeeze dyeing is most common. Although continuous dyeing is carried out for some polyester, the texture becomes hard and flexibility is impaired. In the case of squeeze dyeing, although uneven dyeing occurs if singeing is carried out prior to dyeing since the dyeing properties of melt balls differ from the cloth, in the present embodiment, since melt balls are removed from the cloth surface by polishing, the problem of uneven dyeing does not occur. Dyeing streaks occur if singeing is uneven. In cases when the problem of dyeing streaks attributable to singeing cannot be solved, singeing and polishing may be carried out on the woven fabric after having dyed the weaving yarn. Namely, dyeing may be carried out prior to singeing or after singeing.

[0086] (Finishing Drying)

[0087] Next, the cloth is finished by drying.

[0088] Since a woven fabric or knitted fabric in which anti-pilling measures have been implemented according to the aforementioned manufacturing method has gone through a singeing step and polishing step, when confirmed with an electron microscope as shown in FIGS. 3, 4, 6 and 8, melt balls on the ends of fibers are present on the outside of the spun yarn although embedded within the cloth, and polishing traces are present on the cloth surface that were formed by scraping off the melt balls on the fluff tips.

[0089] As a result of implementing anti-pilling measures including the aforementioned singeing step and polishing step, even in the case of a woven fabric or knitted fabric containing thermoplastic synthetic staple fibers of grade 1 to 2, the anti-pilling measures can improve the pilling resistance grade to grade 3 or higher, preferably grade 4 or higher and even more preferably grade 5 or higher, and the resulting woven fabric or knitted fabric inhibits decreases in strength and worsening of texture. As is indicated in the following examples, a woven fabric or knitted fabric in which the anti-pilling measures of the present embodiment have been implemented also has superior durability since the anti-pilling performance thereof persists even after repeated washing.

EXAMPLES

Example 1

Manufacturing of Spun Polyester Product (Singeing+Polishing)

[0090] Spun polyester fibers (polyester staple fibers, 1.6 denier, cut to 38 mm) were spun in accordance with an ordinary method to obtain polyester spun yarn (yarn count: 30).

[0091] The yarn was warped by using the resulting polyester spun yarn for the warp, warp glue consisting mainly of poval was applied to the warped yarn, and the resulting polyester spun yarn was similarly used for the weft to weave plain-woven gray fabric at a warp density of 90 yarns/inch (2.54 cm) and weft density of 70 yarns/inch.

[0092] After desizing and scouring the resulting gray fabric, both sides of the cloth were singed with a gas singeing machine (80 m/min) to form melt balls on the cloth. Next, both sides of the cloth were polished with a belt sander (#1000 mesh) to remove the melt balls formed on the surface of the cloth. Subsequently, a plain-woven test roll composed of spun polyester fibers was obtained by going through a heat setting step for 1 minute at 180 C., a squeeze dyeing step using squeezing and a drying step.

Comparative Example 1

[0093] A test roll was obtained according to the same method as Example 1 with the exception of omitting the singeing step and polishing step.

Comparative Example 2

[0094] A test roll was obtained according to the same method as Example 1 with the exception of carrying out alkali reduction treatment (10%) instead of the polishing step after the singeing step of Example 1.

Comparative Example 3

[0095] A test roll was obtained according to the same method as Example 1 with the exception of carrying out alkali reduction treatment (20%) instead of the polishing step after the singeing step of Example 1.

Comparative Example 4

[0096] A test roll was obtained according to the same method as Example 1 with the exception of carrying out alkali reduction treatment (30%) instead of the polishing step after the singeing step of Example 1.

Example 2

Manufacturing of Spun Nylon Product (Singeing+Polishing)

[0097] Spun nylon fibers (nylon 66 staple fibers, 1.7 denier, cut to 38 mm) were spun in accordance with an ordinary method to obtain nylon spun yarn (yarn count: 30).

[0098] The yarn was warped by using the resulting nylon spun yarn for the warp, warp glue consisting mainly of poval was applied to the warped yarn, and the resulting polyester spun yarn was similarly used for the weft to weave plain-woven gray fabric at a warp density of 90 yarns/inch and weft density of 70 yarns/inch.

[0099] After desizing and scouring the resulting gray fabric, both sides of the cloth were singed with a gas singeing machine (80 m/min) to form melt balls on the cloth. Next, both sides of the cloth were polished with a belt sander (#1000 mesh) to remove the melt balls formed on the surface sides of the cloth. Subsequently, a test roll composed of spun nylon fibers was obtained by going through a heat setting step for 1 minute at 180 C., a squeeze dyeing step using squeezing and a drying step.

Comparative Example 5

[0100] A test roll was obtained according to the same method as Example 2 with the exception of omitting the singeing step and the polishing step.

Example 3

Manufacturing of Blended Raised Material Product (Singeing+Polishing)

[0101] A pre-dyed cloth (warp 96 yarnsweft 90 yarns), which was woven using twisted yarn comprising two blended yarns (yarn number: 40), obtained by spinning polyester fibers (cut to 38 mm, top dyed) and rayon fibers (cut to 38 mm) at a blending ratio of 65:35, and one polyurethane filament yarn (40 denier) for the warp yarn and weft yarn (final blending ratio: 61:33:6), was prepared followed by further carrying out card cloth raising. Gas singeing (80 m/min was carried out on this cloth to form melt balls, followed by polishing both sides of the cloth with a belt sander (#1000 mesh) to remove the melt balls that had formed on the surface of the cloth. Subsequently, a plain-woven test roll composed of a blended material was obtained by going through a heat setting step for 1 minute at 180 C.

Comparative Example 6

Manufacturing of Blended Raised Material Product (Singeing

[0102] A test roll was obtained according to the same method as Example 3 with the exception of omitting the polishing step.

Comparative Example 7

Manufacturing of Blended Raised Material Product (Regular Processing)

[0103] A test roll was obtained according to the same method as Example 3 with the exception of omitting the singeing step and polishing step.

[0104] An anti-pilling test and tear strength test were carried out on samples without washing, after washing 10 times or after washing 30 times using the test rolls obtained in Examples 1 to 3 and Comparative Examples 1 to 7. However, the tear strength test was omitted for the test rolls obtained in Example 2, Comparative Example 5 and Example 3, while the anti-pilling tests following 10 and 30 rounds of washing were omitted for the test rolls obtained in Comparative Examples 6 and 7. The results are shown in the following Table 1.

[0105] The anti-pilling test was carried out for 10 hours in accordance with Method A of JIS L1076 (method using ICI-type tester). The test results represent the average of the assessment results of four test pieces.

[0106] The tear strength test was carried out in accordance with JIS L1096D (pendulum method).

[0107] Washing was carried out 10 times and 30 times in accordance with Method C4M of JIS L1930 (using tumble drying).

TABLE-US-00001 TABLE 1 Washings Anti-pilling Tear strength Tear strength Test Roll (times) grade (N) (warp) (N) (weft) Example 1 0 5 38.9 30.0 (PE) 10 5 33.5 26.7 30 5 31.3 24.1 Comparative 0 1 39.8 31.4 Example 1 10 1 33.6 29.7 (PE) 30 1 31.3 23.6 Comparative 0 5 16.7 15.1 Example 2 10 5 15.9 14.2 (PE) 30 5 16.2 13.6 Comparative 0 5 13.6 8.3 Example 3 10 5 13.2 11.1 (PE) 30 5 13.3 11.1 Comparative 0 5 7.5 7.1 Example 4 10 5 7.8 6.6 (PE) 30 5 8.1 7.2 Example 2 0 5 * (NY) 10 5 30 5 Comparative 0 1.5 Example 5 10 1.5 (NY) 30 1.5 Example 3 0 4.5 (PE + R) 10 4.5 30 5 Comparative 0 3.5 Example 6 10 (PE + R) 30 Comparative 0 1 Example 7 10 (PE + R) 30 *Not performed

[0108] Based on the results shown in Table 1, the test rolls of Examples 1 to 3 demonstrated the highest anti-pilling grade of 5 even after 30 rounds of washing as a result of having undergone singeing and polishing and exhibited extremely superior pilling resistance, favorable texture were free of decreases in strength. On the other hand, the anti-pilling grade of the test roll of Comparative Example 1, which was manufactured without undergoing singeing and polishing, was grade 1, the anti-pilling grade of the test roll of Comparative Example 5 was grade 1.5, and the anti-pilling grade of the test roll of Comparative Example 7 was grade 1, thereby indicating that a large amount of pilling occurred in the manufacturing stage.

[0109] In addition, in Comparative Examples 2 to 4, which indicate results attributable to alkali reduction treatment that has conventionally been known to be an anti-pilling measure of spun polyester fibers, although preferable results in the form of an anti-pilling grade of grade 5 were obtained in the same manner as Examples 1 and 2, results of the tear strength test were such that tear strength had fallen to roughly only 50% or less of that of Example 1, thereby demonstrating considerable deterioration of cloth strength. Consequently, it was difficult for cloth serving as the material to retain the inherent strength and texture thereof. Moreover, anti-pilling measures based on reduction processing are susceptible to variations in texture and strength due to differences in reduction rates, and are therefore not preferable from the viewpoint of serving as stable anti-pilling measures. In Comparative Example 6, although the anti-pilling grade improved in comparison with Comparative Example 7, demonstrating an anti-pilling grade of 3.5, as a result of a large number of melt balls formed due to singeing being present on the cloth surface, the feel of the cloth on the skin was poor and product value was impaired.

INDUSTRIAL APPLICABILITY

[0110] Since the anti-pilling cloth of the present invention demonstrates extremely superior pilling resistance, favorable texture and does not demonstrate remarkable decreases in strength, it can be preferably used various clothing articles and other textile products having a desired texture and appearance that are woven or knitted fabric using spun yarn comprised of synthetic fibers for which practical application has previously been difficult.

REFERENCE SIGNS LIST

[0111] 1 Reversing roller [0112] 2 Reversing roller [0113] 3 Heated cylinder [0114] 4 Heated cylinder [0115] 5 Heated cylinder [0116] 6 Reversing roller [0117] 7 Reversing roller [0118] 8 Reversing roller [0119] 9 Movable retainer valve [0120] 10 Belt sander [0121] 11 Paper powder remover [0122] 12 Cloth powder remover [0123] 13 Reversing roller [0124] 14 Cloth powder remover [0125] 15 Reversing roller [0126] 16 Guide roller [0127] 17 Guide roller [0128] 18 Reversing roller [0129] 19 Shaking device