EP2530195B1 - Knit or woven fabric, method and thread for producing same and use of same - Google Patents

Description

The present invention relates to a knitted or woven fabric, a process for its preparation and its use. For this purpose, reference is made to the preambles of claims 1, 4, 8 and 9.

The prior art is on the US 2007/0141335 A1 . GB 2 346 624 . US 3,100,926 and US 3,019,017 in which such fabrics and manufacturing processes with expanded, unexpanded but expandable yarns, as well as their use as upholstery fabrics, protective clothing and insulation materials are described.

However, those skilled in the art are always challenged to provide new types and structures for knit fabrics or woven fabrics and their yarns which are achieved by altering their manufacturing parameters, composition and construction in order to meet certain requirement profiles, particularly in terms of appearance and compressibility. A versatile applicability is always desirable.

These objects and problems are surprisingly solved by the subject-matter of claims 1, 4, 8 and 9, respectively.

In the first place, it is therefore of inventive significance that the mesh or woven fabric uses at least one yarn which has a coating or sheathing of expandable, in particular foamable, material. The knitted or woven fabric according to the invention may have this yarn in the already expanded state or may also contain an unexpanded yarn which is increased in volume only at a later time and in particular is subject to foaming. The desired increase in the volume or diameter of the yarn is controlled by temporarily changed environmental conditions. Conceivable changes in the external conditions are, for example, the temperature, the pressure, the humidity and / or the change in the state of aggregation of further present substances, which then cause foaming or swelling of the yarn coating or coating due to the change. Also, for example, a chemical reaction be responsible for this. However, the soul of the yarn remains unaffected, as only the coating or sheathing undergoes spatial enlargement. The diameter of the yarn according to the invention can thus be increased to a multiple and in the range of 1,000% and more.

The clou is therefore to create or use a yarn or to create a textile in which a volume can be achieved with which the yarn can be obtained in a conventional machine for producing textiles, for example a knitted fabric. or weaving machine could not be processed. The yarn according to the invention can thus be processed with conventional machines and the volume of the yarn subsequently increased significantly. This opens up new applications and manufacturing possibilities.

At the same time, bonding of the actual textile and of the expanded volume, for example by fusion or gluing, can take place at the same time. In particular, textile layers can be connected to the expanded volume.

In this case, all the usual textiles, such as knitted or knitted or fabric can be produced. It is particularly advantageous to use spacer knits or composite or climate fabrics in which the yarn according to the invention is arranged between two textile layers. These layers can be knit or weaving connected. This is not necessary. By way of example, a connection can also be made by expanding such that the expanded volume establishes a connection to the textile layers.

The starting point of the invention is formed by a yarn or a method for producing such a yarn. It is known in principle to create jacketed yarns and wound.

The yarn used according to the invention comprises a core and a coating or sheathing of expandable material which due to temporarily adjustable external conditions increases the overall diameter of the yarn causes. This means that in particular the casing performs an expansion, which then leads to an increase in the overall diameter of the yarn. It is not mandatory that this expansion leads in all directions to a uniform or equal expansion. The larger diameter is thus to be understood as an enlarged cross-sectional area or as an enlarged comprehensive overall diameter. At least, however, an increase in the size of the cross-sectional area is effected, whereby also such cross-sectional area areas are counted, which are taken for example by trapped gas bubbles. In particular, the increase is not reversible. In particular, it also remains at elimination of the environmental condition created for expansion. In particular, the volume is at least doubled, in particular the diameter at least doubled or the volume is quadrupled.

Such a yarn can be used in conventional machines for the production of textiles, knitted fabrics, and the like, and subsequently lead to an increase in the diameter of the yarn. This can be used for example to increase the density and / or thickness of the material to be produced. It is also conceivable to effect thereby an increase in the diameter of the yarns dissolving the separate structure of the individual yarns according to the invention and leading to a closed, filled volume. In this case, the increase in the diameter is in particular not permitted the same in all directions in space, so that, in particular in juxtaposed yarns according to the invention such an expansion results, which leads to a fusion of the expanded volume.

Advantageously, after the increase in the diameter, in particular after restoring the original external conditions and / or establishing the conditions of use for the yarn or the material produced therefrom, the expanded volume becomes (again) a solid.

During expansion, especially when it is caused by temperature increase, usually a consistency change of the shell is effected. It will often be viscous or at least deformable so that they can expand or foam. Advantageously, after the expansion, a solid state of the expanded volume or of the expanded coating or sheathing is again caused. However, a solid state does not mean rigid and immobile or incompressible. Rather, preference is given to a state which, although a solid state, ensures mobility and compressibility.

In order to be able to ensure such an expansion, the expandable material contains in particular at least one foaming agent and at least one foam wall former. The foaming agent causes an increase in the volume and secures the Schaumwandbildner the contours, both outer and inner, of the expanded volume. Suitable foaming agents are, in particular, materials containing hydrocarbon, since these are generally thermally activatable. This can be done by evaporation of hydrocarbon, especially in the form of CO ₂ . The at least one foam wall former contains in particular at least one polymer material, in which case a thermoplastic polymer material is chosen in particular since this becomes deformable upon thermal activation and can be converted back into a solid state when the temperature is lowered. In addition, a thermoplastic polymer material may also be used to form a bond to the surrounding textile, knit and / or fabric layers. In particular, the expandable material comprises at least one foaming agent and a foam wall former. Additional additions can be added to this.

With particular advantage, the foaming agent is at least partially encapsulated, in particular in hollow spheres in the expandable material. In particular, thermoplastic hollow spheres are used. In such a case, the hollow spheres or their shell can be part of the foam wall former at the same time.

When thermoplastic hollow spheres are used by thermal activation, not only activation of the foaming agent or evaporation can take place can be achieved by hydrocarbons, but it can also be their propagation by softening the thermoplastic hollow spheres and by making the foam forming wall deformable a reliable function of the yarn according to the invention can be realized in a simple manner.

Advantageously, the yarn has thermosplastic polymer materials as foam wall formers and encapsulated hydrocarbon droplets in thermoplastic hollow spheres forming microspheres. As the temperature increases, they begin to evaporate and lead to expansion of the microspheres. As a result, even without destroying the microspheres, an expansion can be ensured. Also, an independent curing, especially when lowering the temperature, possible.

Advantageously, the hydrocarbon droplets evaporate according to claim 10 at a temperature range of 170 ° -180 °. This is particularly favorable, since such temperatures are not reached in the manufacturing process, but the fabric or textile, the fabric or knitted fabric, however, usually do not damage either. Also, at such temperatures a particularly good deformability of thermoplastics can be ensured. Also, at such temperatures a particularly good connection between the actual textile or fabric or fabric or knitted fabric and the foam wall formers, in particular thermoplastics possible.

Advantageously be microspheres of Espancel ^® in admixture with an ethylene vinyl acetate, especially ethylene vinyl acetate used including high and low viscosity, as the expandable material. This has proven to be a particularly reliable mixture, which is thermally activated.

Advantageously, the yarn is chosen so that its diameter after coating or sheathing, but before expansion of the expandable material, is in the range of 1 to 2 mm, in particular 1.4 mm. The sheathing is chosen so that advantageously after carried out expansion, a diameter in the range of 4-6 mm, in particular of 5 mm, achieved becomes. The weight per unit area may in particular be between 200 and 1,000 g / m 2.

A method for producing a covered or coated yarn includes or comprises the following steps. First, an expandable material is compounded. This is usually done by mixing at least one foam wall former and at least one foaming agent. Advantageously, the expandable material is melted in extruders and mixed, and in particular subsequently granulated again. Alternatively, an expandable material may be provided. This is followed by overmolding of a yarn core, in particular of plastic with the expandable material. In this case, a coated or coated yarn is produced. The encapsulation does not have to take place over the entire length or over the entire circumference of the yarn. For special applications, an exclusively partial encapsulation of a yarn core is conceivable. Thus, for example, this can be extrusion-coated only in an angular segment, for example half-sided or only in certain sections. For extrusion coating, an extrusion spinning system, in particular with a cross-spray head and / or pressure-coating or coating tool, is advantageously used. Such systems are, in particular from the cable industry, known in the art and can thus be used according to the invention.

The object is achieved by a knit fabric or woven fabric, in particular in the form of a knitted or knitted fabric, comprising at least one inventive yarn in the expanded and / or unexpanded, but expandable state. Such a knit or woven fabric does not necessarily have to be a textile. Also, the use of other fibers for the production of a knit fabric or fabric is conceivable. It is also largely unessential in which form and / or arrangement at least one inventive yarn is included. Advantageously, however, the yarn has a certain connection to the rest of the mesh and / or woven fabric. Although in principle it is conceivable simply to hang up the yarn or to arrange it in another way adjacent and by a later, in particular during the expansion or after the expansion to make a connection to the mesh or woven fabric. However, according to the invention, the yarn is knitted or weaving in particular with the knit fabric or woven fabric, so that a secure connection is ensured even before or during expansion.

Depending on the application, the knit fabric or woven fabric fulfills its function both in the expanded and / or unexpanded state. In the expanded state, for example, a finished product, such as an insulating material can be created. In the unexpanded state, it is possible, for example, to create a raw product or also a product for adaptation to a shape and subsequent expansion. It is also conceivable that an expansion takes place during the use of the knit fabric or woven fabric. This can be done, for example, by the action of heat, especially in or near fire, or when in contact with a medium, such as e.g. Water, done. Thus, certain protective functions can be realized by such a mesh fabric or woven fabric. In principle, a knit fabric or woven fabric with unexpanded yarn according to the invention is significantly more permeable to gases, liquids and thermal radiation than knit fabric or woven fabric with expanded yarn.

The at least one yarn is inventively included as a weft, filling and / or insert yarn in the mesh or woven fabric. In particular, it is advantageously included within a conventional spacer knit, fabric or knit fabric. For this purpose, the spacer fabric / fabric / knit or composite or Klimasteppjersey in particular an upper and a lower, but at least two, sides or layers to form a gap between or in which the yarn is inserted or fixed there. In particular, the yarn is inserted there straight and in particular parallel to each other, in particular unmasched. According to the invention, however, connections between the individual layers, between which the yarn is inserted, are provided. Such are advantageously introduced directly in the production of the mesh or woven fabric. You can, however also subsequently, for example, be effected by seams. The compounds are chosen or designed so that after expansion of the at least one yarn through these compounds, a constriction of the woven fabric or knit fabric is effected. This means that the compounds in cooperation with the respective layers restrict the expansion of the yarn at least in one spatial direction.

By such a connection, the cohesion of the mesh fabric and / or woven fabric is guaranteed. As a result, the position of the inserted yarns is secured if they are not even or only little meshed or secured in any other way. Also, such a grid can be created by such compounds, within which also the lateral offset of the yarns can be restricted.

Constrictions of the woven fabric or knit fabric not only lead to a preferred appearance, but also ensure a special compressibility, since they can lead to a bias in the expanded volume and / or mesh or woven fabric.

Advantageously, a plurality of yarns, in particular runs parallel. As a result, the advantages of the yarn according to the invention can be utilized not only locally but over a wide area or over the entire knit fabric or woven fabric.

Advantageously, the expansion of the at least one yarn in the knit or woven fabric according to the invention leads to an increase in the thickness of the knit fabric. In particular, an enlargement of the distance between an upper and a lower layer, but at least between two layers is achieved. In this case, this increase in the distance does not take place over the entire surface. In particular, it may also be constricted by sections between the layers or completely prevented in sections. This is to be preferred, in particular if a tension is exerted on the connections or a pressure that presses the layers apart is caused by this restriction or prevention.

Such a bias in the mesh or woven material leads to a particularly adjustable compressibility, such as in seats, leads to a special comfort.

The object is also achieved by a method for producing a woven fabric or knit fabric, in particular one in the form of a knitted or knitted fabric, in which at least one yarn is used. In this case, the yarn is at least not fully expanded state. This means that the yarn can at least be further expanded by appropriate influences. It is introduced as a weft, insertion and / or filling thread. In this case, a plurality, in particular parallel, inventive or inventively produced yarns are advantageously used. These are in particular unmasched and introduced in particular as an intermediate layer. Subsequently, an expansion of the at least one yarn is effected. The expansion takes place after shaping, molding, processing and / or installation of the woven fabric or knit fabric. This makes it possible to achieve a special form faithfulness in a simple way. In particular, the at least one yarn is subsequently set in a solid state by setting the ambient condition. Such an expansion produces a particularly advantageous woven fabric or knit fabric in a simple manner.

According to the invention, at least two woven fabric and / or mesh fabric layers are provided during production, which compounds, in particular punctiform and / or linearly arranged (also karoförmig), to each other. In this case, the at least one yarn is arranged between these layers. As a result, a firm connection of the woven fabric and / or knit fabric and the yarn or yarn according to the invention is produced, even if no other compounds are provided. In this case, the connections are dimensioned such that they at least limit the expansion of the at least one yarn in cooperation with the layers and so in particular a tension of the compound and / or the layers is effected. In this way, a self-prestressed woven fabric or knit fabric can be obtained in a simple manner.

As a soul, for example, polyester, polyamide, cotton, cellulose, polypropylene, PLA, PVA and in particular with a titre of Nm 5 to Nm 100 or synthetic souls dtex 50 to dtex 400 in question.

The object is also achieved by a method for producing a cover or clothing, boarder for mattresses, also mattress covers, hygiene products, water sports products, life jackets, buoyancy aids, insulation material, protective clothing or armchair or chair, an automotive interior trim and automobile seats, a wall covering having a cover thereby in that the cover or the garment comprises or consists of knitted or woven fabric according to one of claims 1 to 3. In this case, the expansion of the yarn is carried out only after sewing, gluing, molding and / or molding of the knit fabric, woven fabric or yarn and the yarn is set after expansion by adjusting the environmental conditions in a solid state, if such does not exist anyway. For the solid state above applies. He does not have to be stiff. In particular, the expansion is performed so that a bias in the mesh or woven fabric is generated.

The object is also achieved by use of the knitted or woven fabric according to one of claims 1 to 3 as upholstery for armchairs and chairs, as automotive interior trim, mattress cover, wall covering, mattress boards, hygiene products, water sports products, life jackets, buoyancy aids, insulation material, protective clothing and / or clothing.

In such a use, the advantages of the substance according to the invention come particularly to advantage.

Fig. 1

eine etwas vergrößerte fotografische Draufsicht auf einen Ausschnitt eines erfindungsgemäßen Maschenstoffes in Form eines Gestricks, bei dem die erfindungsgemäß ummantelten nicht aufgeschäumten Garne parallel nebeneinander liegend ein Abstandsgestrick durchlaufen und seitlich herausragen;

Fig. 2

eine fotografische Draufsicht auf den Ausschnitt des in Fig. 1 gezeigten Maschenstoffs in Form eines Gestricks, das in senkrechter Richtung gedehnt worden ist und die horizontal durch das Abstandsgestrick laufenden ummantelten, nicht aufgeschäumten Garne gut zeigt;

Fig. 3

eine etwas vergrößerte fotografische Draufsicht auf einen Ausschnitt eines erfindungsgemäßen Maschenstoffes, in Form eines Gestricks, bei dem die erfindungsgemäß ummantelten Garne aufgeschäumt sind und bei dem die zwei Lagen des Abstandsgestricks durch karoartig angeordnete Verbindungen zusammengehalten werden;

Fig. 4

eine etwas vergrößerte fotografische Perspektivansicht von der Seite des in Fig. 3 gezeigten erfindungsgemäßen Maschenstoffes in Form eines Gestricks; und

Fig. 5

eine schematische, vergrößerte Darstellung in Form eines Querschnitts durch das erfindungsgemäß ummantelte Garn in seinem nichtexpandierten (A) und expandierten (B) Zustand.

Further advantages and features of the invention will become apparent from the claims and in particular from the following description of an embodiment, which is intended to illustrate the invention and not limited in any way. It shows:

Fig. 1

a somewhat enlarged photographic plan view of a section of a knit fabric according to the invention in the form of a knitted fabric, at in which the non-foamed yarns sheathed according to the invention pass through a spacer knit fabric parallel to one another and protrude laterally;

Fig. 2

a photographic top view of the detail of the in Fig. 1 shown knitted fabric in the form of a knitted fabric which has been stretched in the vertical direction and the horizontal running through the spacer knitted coated non-foamed yarns well;

Fig. 3

a somewhat enlarged photographic plan view of a section of a mesh fabric according to the invention, in the form of a knitted fabric, in which the yarns sheathed according to the invention are foamed and in which the two layers of spacer knit are held together by karoartig arranged connections;

Fig. 4

a slightly enlarged photographic perspective view from the side of the in Fig. 3 shown mesh fabric according to the invention in the form of a knitted fabric; and

Fig. 5

a schematic, enlarged view in the form of a cross section through the present invention sheathed yarn in its unexpanded (A) and expanded (B) state.

Fig. 1 shows a photographic plan view of a section of a fabric according to the invention. Evident is a knitted fabric 10 which includes sheathed yarns 12 according to the invention. These are inserted parallel in a gap 20 between an upper layer 16 and a lower layer 14.

Fig. 2 shows an enlarged section Fig. 1 where the knitted fabric 10 in the illustration in Fig. 2 for ease of illustration was stretched slightly in the direction perpendicular to the yarns 12 according to the invention. Evident is the knitted fabric 10 with its individual stitches and the parallel inserted in a gap 20 yarns 12th

Fig. 3 shows a plan view of a fabric 10 with line-shaped and crossing arranged connections 18, which lead to a constriction and form a karoartiges pattern. Shown here is the knitted fabric 10 after an expansion of the yarn 12. Individual fibers or components of the expanded yarn 12 can be seen hanging out from the side.

Fig. 4 shows a cross section through the fabric 10 with expanded yarns Fig. 3 , Evident are the constrictions caused by the connections 18. Evident are also the upper layer 16 and the lower layer 14 and the filled and expanded by the expansion gap 20.

Fig. 5 shows a schematic view of an expanded yarn ( Fig. 5b ) and an unexpanded yarn ( Fig. 5a ). The soul 22 as well as the sheathing or coating 24 can be seen in each case. It is in each case an inventive yarn 12 which has been foamed by the temperature increase (from FIG Fig. 5a to Fig. 5b ).

LIST OF REFERENCE NUMBERS

10

knitted

12

yarn

14.16

lower, upper layer

18

links

20

gap

22

soul

24

Coating or sheathing

Claims (9)

1. Mesh fabric or woven fabric (10), containing at least one yarn (12), comprising a core (22) and a coating or sheathing (24) of expandable material that, due to temporary, external adjustable conditions, effects an increase in the overall diameter of the yarn in the expanded and/or not-expanded but expandable state, wherein the at least one yarn (12) is included as weft thread, wadding thread and/or inlaid thread, characterised in that it is laid within a spacer knitted fabric, spacer woven fabric or spacer interlaced fabric with two layers (14, 16), which are separated from each other by the formation of an intermediate space (20), is inserted into the intermediate space (20) and that connections (18) between the layers (14, 16) are provided which lead to a constriction of the woven fabric or mesh fabric (10), after expansion of the at least one yarn (12) and wherein the connections (18) are so calculated that they, in interaction with the layers (14, 16), limit the expansion of the at least one yarn (12).
2. Mesh fabric or woven fabric (10) according to claim 1, characterised by the form of a knit such as right/left knitted fabric, right/right knitted fabric, or left/left knitted fabric, interlaced fabric, composite material or climate-control quilted jersey.
3. Mesh fabric or woven fabric (10) according to claim 1 and/or claim 2, characterised in that the weft thread, wadding thread and/or inlaid thread is laid straight and unmeshed into the intermediate space (20).
4. Method for the manufacture of a mesh fabric or woven fabric (10) with connections (18) between two layers (14, 16) which, by the formation of an intermediate space (20), are separated from each other wherein at least one or a plurality of parallel-running yarns (12), each comprising a core (22) and a coating or sheathing (24) of expandable material that, because of temporarily adjustable external conditions, cause an increase in the overall diameter is brought in at least the not completely expanded state as weft thread, inlaid thread and/or wadding thread into the intermediate space (20) and then after forming, impressing, processing and/or insertion of the mesh fabric or woven fabric (10), an expansion of the at least one yarn (12) is effected, wherein the expansion is so performed that after the expansion of the at least one yarn (12) the connections (18) lead to a constriction of the woven fabric or mesh fabric (10), and wherein the connections (18) are so calculated that they, in interaction with the layers (14, 16), limit the expansion of the at least one yarn (12).
5. Method according to claim 4, characterised in that the weft thread, inlaid thread and/or wadding thread is brought in straight and unmeshed as intermediate layer.
6. Method according to claims 4 and/or 5, characterised in that the expansion of the at least one yarn (12) is effected by a temporary rise in temperature.
7. Method according to claims 4 to 6, characterised in that two mesh fabric layers or woven fabric layers (14, 16) are created, which have point-shaped and/or line-shaped connections (18), wherein the connections (18) are so calculated that they, in interaction with the layers (14, 16), limit the expansion of the at least one yarn (12).
8. Method for manufacturing a covering or border for mattresses, hygiene products, water sport products, life jackets, swimming aids, insulating material, protective clothing or clothing or armchairs, chairs, of automobile interior lining and automobile seat coverings, of a covering for a wall cladding, characterised in that the covering or clothing, product or fabric contains or comprises a mesh fabric or woven fabric (10) according to one of the claims 4 to 7 manufactured according to one of the claims 1 to 3 and wherein the expanding of the yarn (12) only takes place once the mesh fabric or woven fabric (10) or yarn (12) has been sewn, glued, impressed and/or formed and the yarn (12) has been converted into a fixed state by the setting of the environmental conditions.
9. Use of the mesh fabric or woven fabric (10) according to one of the claims 1 to 3 as covering material for armchairs and chairs, as automobile interior lining and automobile seat covering, mattress coverings, wall cladding, borders for mattresses, hygiene products, water sport products, life jackets, swimming aids, insulation material, protective clothing and/or clothing.

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