Technical Field
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The present invention relates to a manufacturing method for clothing or bedding by a sewing machine using an upper thread and a lower thread, and clothing or bedding manufactured by the method.
Background Art
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In recent years, recycling of sewn products, especially clothing, has begun to attract attention. In order to disassemble a sewn product, it is most efficient to dissolve a sewing thread. Accordingly, there has also been filed an application relating to clothing formed by joining each portion formed of insoluble fibers with a soluble fiber thread (for example, see Patent Literature 1).
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With clothing in Patent Literature 1, the clothing is put into moisture having a medium-to-high temperature to dissolve a soluble fiber thread, so that only each portion of the clothing formed of the insoluble fiber can be left and recovered. Specifically, the clothing is completed by sewing each clothing part such as a bodice and a sleeve, which is formed of insoluble fibers in warm water, an alkaline solution, or the like, with a sewing machine thread having solubility in warm water, an alkaline solution, or the like.
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As the soluble sewing machine thread, a fiber thread formed of a polyvinyl alcohol-based fiber easily dissolved by immersion in warm water, an alkaline solution, or the like is used (for example, see Patent Literature 2).
Citation List
Patent Literatures
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- Patent Literature 1: Japanese Patent Application Laid-Open No. H8-81811
- Patent Literature 2: Japanese Patent Publication No. S43-8992
Summary of Invention
Technical Problem
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However, as described above, in a case where the sewing is performed by using the water-soluble polyvinyl alcohol-based soluble fiber thread as the sewing machine thread used for sewing, in a case where the obtained sewn product is used in a high-temperature and high-humidity environment, there is a concern that the sewing thread that joins each sewing material (fabric piece) of the sewn product may dissolve, and the sewn product may be fragile.
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An object of the present invention is to provide clothing or bedding that has both strength in use in a high-temperature and high-humidity environment and ease of disassembly into each portion, in view of the problem described above in the related art.
Solution to Problem
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According to an aspect of the present invention, there is provided a manufacturing method for clothing or bedding including: sewing a sewing material with a sewing machine using an upper thread and a lower thread to manufacture clothing or bedding, in which as the upper thread, a water-insoluble sewing thread formed of cotton, silk, a chemical fiber, or a blended fiber is used, as the lower thread, a water-soluble sewing thread using polyvinyl alcohol as a raw material is used, and the lower thread is obtained by performing twisting processing on a thread formed of a water-soluble polyvinyl alcohol fiber by a solvent wet cooling gel spinning method, under a twisting condition in which a ratio of the number of times of upper twisting to the number of times of lower twisting is in a range of 94% to 108%. In addition, according to another aspect of the present invention, there is provided clothing or bedding manufactured by the manufacturing method for clothing or bedding according to the present invention.
Effects of the Invention
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With the present invention, even in a case where the clothing or bedding is used in a high-temperature and high-humidity environment, the upper thread exposed on a front side of the clothing or bedding is not dissolved, and thus reliable joining between the sewing materials is ensured, whereby toughness of the clothing or bedding can be maintained. On the other hand, in a case of disassembling the clothing or bedding into each sewing material, the lower thread is dissolved by exposing the lower thread exposed on a back side of the clothing or bedding to moisture, and thus the clothing or bedding can be easily disassembled into each sewing material.
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In addition, since the lower thread is obtained by executing twisting processing on a thread formed of a water-soluble polyvinyl alcohol fiber by a solvent wet cooling gel spinning method, under a twisting condition in which a ratio of the number of times of upper twisting to the number of times of lower twisting is in a range of 94 to 108 [%], the lower thread can be used as an appropriate sewing machine thread.
Brief Description of Drawings
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- FIG. 1 is an enlarged cross-sectional view illustrating a cross section along a sewing machine thread of clothing or bedding manufactured by a manufacturing method for clothing or bedding according to the present invention.
- FIG. 2 is a table illustrating results of an experiment in which a sewing machine thread is obtained by performing twisting processing on a water-soluble sewing thread using polyvinyl alcohol as a raw material.
- FIGS. 3A to 3C are diagrams illustrating the degree of twisting that may occur for each of an appropriate sewing machine thread, a slightly inappropriate sewing machine thread, and an inappropriate sewing machine thread, which are obtained by the experiment in FIG. 2.
Description of Embodiments
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An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is an enlarged view of a cross section taken along a sewing machine thread of clothing or bedding manufactured by a manufacturing method for clothing or bedding according to the embodiment of the present invention. As illustrated in FIG. 1, a sewn product 1 is manufactured by joining each sewing material 4 constituting clothing or bedding 1, with a sewing machine using an upper thread 2 and a lower thread 3. As the upper thread 2, a water-insoluble sewing thread formed of cotton, silk, a chemical fiber, or a blended thread is used.
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As the lower thread 3, a water-soluble sewing thread using polyvinyl alcohol as a raw material is used. Specifically, a thread obtained by executing twisting processing (lower twisting and upper twisting) on a thread (see
Japanese Patent Publication No. 43-8992 ) formed of a water-soluble polyvinyl alcohol fiber obtained by a solvent wet cooling gel spinning method is used as the lower thread 3.
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In addition, as the lower thread 3, for example, a thread dissolved in warm water of approximately 40°C to 100°C can be used, but in order to ensure a strength of the lower thread 3 in a case of use in a humid environment, it is preferable to use a thread that has a low saponification degree and is dissolved in warm water of 70°C or higher. Each sewing material 4 sewn with the upper thread 2 and the lower thread 3 is formed of a water-insoluble fiber. In addition, as the sewing machine using the upper thread 2 and the lower thread 3, for example, a sewing machine can be used.
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Meanwhile, as a sewing machine thread used in the sewing machine, in a case of a general sewing machine thread such as cotton or silk, a sewing machine thread in which a ratio of the number of times of upper twisting to the number of times of lower twisting is set to approximately 70 [%] is used. However, in a case of a sewing machine thread that is formed of a water-soluble polyvinyl alcohol fiber as a raw material by the solvent wet cooling gel spinning method described above and is dissolved at 70°C or higher, it has been found that a twisting condition cannot be applied according to the following experiment by the present inventor.
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FIG. 2 illustrates experimental results obtained by examining a relationship between a twisting condition in a case where a water-soluble polyvinyl alcohol fiber thread obtained by the solvent wet cooling gel spinning method described above is subjected to twisting processing to obtain a sewing machine thread and a suitability of the obtained sewing machine thread. The results of whether the sewing machine thread obtained under each twisting condition was appropriate (∘), slightly inappropriate (Δ), or inappropriate (×) are illustrated. In addition, the results using two types of threads of No. 60 and No. 30 are illustrated.
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Each of FIGS. 3A to 3C illustrates twisting occurring in a sewing machine thread, which is determined to be appropriate (∘), slightly inappropriate (Δ), or inappropriate (×). In a case where the sewing machine thread is appropriate (∘), the sewing machine thread is not twisted as illustrated in FIG. 3A. In a case where the sewing machine thread is slightly inappropriate (Δ), twisting occurs as illustrated in FIG. 3B. In a case where the sewing machine thread is inappropriate (×), as illustrated in FIG. 3C, considerable thread twisting occurs, and the sewing machine thread is not appropriate.
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In the experiment in FIG. 2, as the twisting conditions, conditions in which a plurality of types of upper twisting having different numbers of times with respect to lower twisting of 650 [T/m] is performed are adopted. In FIG. 2, a ratio [%] of the number of times of each upper twisting in a case where the number of times of lower twisting of 650 [T/m] is set to 100 [%] is also illustrated.
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Upper twisting of 455 [T/m] in FIG. 2 (a ratio of the number of times of upper twisting is 70 [%]) corresponds to a twisting condition applied to the general sewing machine thread. Regarding the sewing machine thread obtained under the conditions described above, the result of "inappropriate (×) as the sewing machine thread" is obtained in any case of No. 60 thread and No. 30 thread. In addition, the result of the inappropriate (×) is also obtained for upper twisting of 768 [T/m] (118 [%]).
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On the other hand, in a case where upper twisting is 610 [T/m] or 704 [T/m], the result is that the sewing thread is slightly inappropriate (Δ), and in a case where the upper twisting is 620 [T/m], 640 [T/m], 650 [T/m], 660 [T/m], 672 [T/m], or 682 [T/m], the result is that the sewing thread is appropriate (∘).
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As illustrated in FIG. 2, the appropriate twisting conditions in a case where twisting processing is performed on a thread, which is formed of a water-soluble polyvinyl alcohol fiber as a raw material by a solvent wet cooling gel spinning method and is dissolved at 70°C or higher, to obtain a sewing machine thread are present in a range in which, at lower twisting of 650 [T/m], a ratio of the number of times of upper twisting to the number of times of lower twisting is within a range of 95% to 105%.
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In addition, the twisting conditions including a case where the sewing machine thread is slightly inappropriate are present in a range in which the same ratio is within a range of 94 to 108 [%]. On the other hand, in a range in which the ratio is 70% or less or 118% or more, it is determined that there are no appropriate twisting conditions. That is, under the twisting conditions in this range, sewing is possible, but as illustrated in FIG. 3C, over-twisting occurs, which is not preferable since over-twisting causes a failure in sewing.
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In a case of manufacturing the clothing or bedding 1, first, as the upper thread 2, a sewing thread formed of cotton, silk, a chemical fiber, or a blended fiber, on which appropriate twisting processing is executed, is prepared. In addition, as the lower thread 3, the lower thread 3 on which twisting processing under the appropriate twisting conditions illustrated in FIGS. 2 and 3A to 3C is executed and which is dyed in an environment of a low temperature lower than the dissolving temperature is prepared. Since the lower thread 3 is less noticeable than the upper thread in many cases, the dyeing may be omitted, the steps may be simplified, and manufacturing costs may be reduced.
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Next, the upper thread 2 and the lower thread 3 are set in a sewing machine, for example, a sewing machine, with which sewing is performed by using the upper thread 2 and the lower thread 3. Then, joining portions of the two sewing materials (fabric piece) 4 joined by the upper thread 2 and the lower thread 3 are overlapped and disposed at a predetermined position of the sewing machine, and the sewing machine is driven to join the two sewing materials 4 with the upper thread 2 and the lower thread 3.
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As a result, the two sewing materials (fabric pieces) 4 are joined as illustrated in FIG. 1. In this manner, the sewing materials 4 are repeatedly joined, and the clothing or bedding 1 in a state in which the upper thread 2 is exposed on a front surface side of the clothing or bedding 1 and the lower thread 3 is exposed on a back surface side is manufactured.
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On the other hand, in a case where the clothing or bedding 1 is disassembled for each sewing material (fabric piece) 4, the clothing or bedding 1 is easily disassembled by exposing the lower thread 3 to moisture to dissolve the lower thread 3. The exposure of the lower thread 3 to water is performed, for example, by storing the clothing or bedding 1 in a storage bag and immersing the clothing or bedding 1 in warm water, for example, 95°C, which is filled in a dissolution tank, for approximately 30 minutes. In this case, in order to promote the dissolution of the lower thread 3, for example, a nonionic surfactant may be added to the warm water in an amount of approximately 0.01 to 20 [g/liter].
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As a result, the lower thread 3 is dissolved while a shape of the clothing or bedding 1 is maintained by the storage bag, and the clothing or bedding 1 is disassembled for each sewing material (fabric piece) 4. The disassembled sewing material (fabric piece) 4 is reused.
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In a case of exposure of the lower thread 3 to moisture, steam at 100°C or higher, warm water supplied from a hose or a funnel, or the like may be used. In addition, the moisture applied to the lower thread 3 portion with an iron or the like may be heated to a temperature at which the lower thread 3 is dissolved. In addition, a jig for holding the clothing or bedding 1 may be used to easily expose the lower thread 3 to moisture.
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With the present embodiment, even in a case where the clothing or bedding 1 is used in a humid environment, the upper thread 2 exposed on a front side of the clothing or bedding 1 is water-insoluble, and the joining between the sewing materials 4 is ensured, whereby toughness of the clothing or bedding 1 can be maintained. On the other hand, since the lower thread 3 exposed on a back side of the clothing or bedding 1 is a water-soluble sewing thread made of polyvinyl alcohol as a raw material, the clothing or bedding 1 can be easily disassembled into each sewing material 4 and reused by exposing the lower thread 3 to moisture.
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In addition, the lower thread 3 is obtained by executing twisting processing on a thread formed of a polyvinyl alcohol fiber that can be dissolved in warm water of 70°C or higher by the solvent wet cooling gel spinning method, under a twisting condition in which a ratio of the number of times of upper twisting to the number of times of lower twisting is in a range of 94% to 108%, and thus the lower thread 3 can be used as an appropriate sewing machine thread.
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In addition, since the lower thread 3 is dyed in an environment at a temperature lower than a temperature at which the lower thread 3 is dissolved, a brightness, a chroma saturation, and hue of the clothing or bedding 1 as viewed from the upper thread 2 side can be optionally adjusted, according to the brightness, the chroma saturation, and the hue of the dyeing. Since a color of the lower thread 3 does not have a significant effect on an appearance from the upper thread 2 side, the dyeing of the lower thread 3 may be omitted to improve productivity.
Description of Reference Numerals
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- 1: clothing or bedding
- 2: upper thread
- 3: lower thread
- 4: fabric piece