HK1237005B - Method for weaving multiply gauze, and multiply gauze woven fabric - Google Patents

Description

Method for manufacturing multi-layer yarn and multi-layer yarn fabric

Technical Field

The present invention relates to a method for manufacturing multi-layer yarn and a multi-layer yarn fabric manufactured by the method.

Background Art

Gauze is a type of plain fabric woven from relatively fine yarns. Gauze is characterized by its lightness and breathability.

When gauze fabrics are used as fabrics for clothing or bedding in order to utilize the above characteristics, there is room for improvement in terms of barrier properties (not easily visible through), heat retention, water absorption, and softness.

Multilayer yarns, made by overlapping two or more yarns, showed improved barrier properties. On the other hand, while the overlapping yarns improved heat retention and water absorption, they did not significantly improve. Softness was not improved at all.

Among gauze fabrics that are excellent in terms of barrier properties, heat retention, water absorbency, and softness, there is toweling yarn (gauze towel or terry yarn) (Patent Document 1).

Patent Document 1: Japanese Patent Application Laid-Open No. 2000-220058

Summary of the Invention

Although towel yarn has the advantages of both yarn and towel, it must have terry, so when used as cloth for clothes or bedding, it is not light. In other words, the lightness and breathability that are the characteristics of yarn fabrics cannot be utilized.

In view of the above, the problem to be solved by the present invention is to provide a gauze fabric which has excellent barrier properties, heat retention, water absorption and skin touch (softness) while maintaining lightness and breathability.

In order to solve the above problems, the present invention provides a method for manufacturing multi-layer yarn, including: supplying warp yarn from a first warp beam to form a tensioned A layer; supplying warp yarn from a second warp beam at a supply speed faster than the supply speed of the first warp beam to form a B layer that is looser than the A layer; and forming a connecting portion connecting the A layer and the B layer.

In the above invention, preferably, the feeding speed of the second warp beam is 0.5 to 5.0% faster than the feeding speed of the first warp beam.

In the above invention, preferably, the multi-layer yarn includes multiple layers, and the multiple layers include a surface layer, a middle layer and a back layer.

forming the A layer in the intermediate layer,

The B layer is formed on the surface layer and the back layer.

In the above invention, it is further preferred that the connecting portion comprises: a first connecting portion regularly connecting the surface layer and the middle layer; and a second connecting portion regularly connecting the back layer and the middle layer.

The first connecting portion is formed at a position corresponding to a middle position between two adjacent second connecting portions.

In the above invention, it is further preferred that the connecting portion comprises: a first connecting portion regularly connecting the surface layer and the middle layer; and a second connecting portion regularly connecting the back layer and the middle layer.

The first connecting portion is formed at a position corresponding to the second connecting portion.

In order to solve the above problems, the present invention provides a multi-layer yarn fabric, including: a layer A formed by tensioning the warp yarn supplied from a first warp beam; a layer B formed by loosening the warp yarn supplied from a second warp beam at a supply speed faster than the supply speed of the first warp beam than the A layer; and a connecting portion connecting the A layer and the B layer.

In order to solve the above problems, the present invention provides a garment formed of the above multi-layer gauze fabric.

In order to solve the above problems, the present invention provides a bedding product formed by the above multi-layer gauze fabric.

The multi-layer gauze fabric of the present invention is superior to conventional multi-layer gauze fabrics in terms of barrier properties, heat retention, water absorption, air permeability, and skin feel (softness).

The multi-layer gauze fabric of the present invention can maintain the lightness of conventional multi-layer gauze fabrics.

The result is a fabric suitable for use as clothing and bedding.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a cross-sectional view of a double-layer gauze fabric according to a first embodiment of the present invention.

FIG2 is a cross-sectional view of a double-layer gauze fabric according to the prior art.

FIG3 is a cross-sectional view of a triple-layer gauze fabric according to a second embodiment of the present invention.

FIG4 is a cross-sectional view of a triple gauze fabric according to a third embodiment of the present invention.

DETAILED DESCRIPTION

<First embodiment>

The structure and manufacturing method of the yarn are described below.

Fig. 1 is a cross-sectional view of a multi-layer gauze fabric according to a first embodiment of the present invention. Although the present invention is an N-layer gauze fabric (N is an integer greater than or equal to 2), a double-layer gauze fabric will be described for easier understanding of the present invention.

Double-layer yarn fabrics include a surface layer and a back layer.

The surface layer yarn is formed by warp yarns (longitudinal yarns) 1 and 2 and weft yarns (horizontal yarns) 3 and 4.

The warp yarns 1 and 2 of the surface layer are fed from a first warp beam. The warp yarn feeding speed of the first warp beam is equivalent to the feeding speed in normal yarn production.

At this time, the tension of the warp yarns 1 and 2 is also adjusted according to the warp yarn supply speed.

The weft yarns 3 and 4 are inserted according to the supply of the warp yarns, thereby forming a taut A layer (normal yarn).

The back layer yarn is formed by warp yarns (longitudinal yarns) 5 and 6 and weft yarns (horizontal yarns) 7 and 8.

The back layer warp yarns 5 and 6 are fed by a second warp beam. The feeding speed of the second warp beam is 0.5 to 5.0% faster than that of the first warp beam, preferably 1.5 to 3.0% faster.

At this time, the tension of the warp yarns 5 and 6 is adjusted to be 0.8 times or less of the tension of the warp yarns 1 and 2 according to the warp yarn supply speed. Preferably, it is adjusted to be 0.6 times or less.

The weft yarns 7 and 8 are inserted according to the supply of the warp yarns. Thus, the B layer which is looser than the A layer is formed.

The number of weft yarns 3 and 4 is the same as that of weft yarns 7 and 8, and they are inserted at the same intervals.

Because the second warp beam is fed faster than the first, warp yarns 5 and 6 are longer than warp yarns 1 and 2. Meanwhile, the warp yarn lengths of layers A and B are the same. Consequently, layer B is looser than layer A.

Simultaneously with the formation of layer A and layer B, layers A and B are appropriately joined. The joining portion can be formed by warp yarns or weft yarns. In the example shown in the figure, warp yarn 2 is interwoven with weft yarn 8, while warp yarn 5 is interwoven with weft yarn 4, thereby forming joining portion 10.

The effects are described below.

Figure 2 is a double-layer yarn fabric formed by overlapping two pieces of ordinary yarn (prior art). The effect of this embodiment will be explained by comparing it with the prior art.

The following describes improvements in barrier properties, heat retention, water absorption, and air permeability.

In the prior art, a single warp beam feeds both the front and back warp yarns. Consequently, the feed speeds for both warp yarns are identical. The result is a flat double-layer yarn. With no space between the two yarns, improvements in barrier properties, thermal insulation, and water absorption are due to the overlap of the two yarns, without significant improvement. Air permeability is also reduced due to the overlap of the two yarns.

In contrast, the first embodiment has a loose B layer, creating a space between the two yarns. By using two thin yarns, the thickness of the double yarn layer can be maintained. This space and thickness improve barrier properties, heat retention, water absorption, and breathability compared to conventional techniques.

As a result, it is suitable as fabric for clothing (robes, pajamas, shirts, pants, baby products, etc.) and bedding (sheets, blankets, pillowcases, etc.).

For example, it provides breathability in hot summer and heat retention in cold winter, so the user can actually feel warm in winter and cool in summer.

When used as pajamas or bed sheets, the space absorbs sweat while sleeping, while its breathability allows excess body heat to escape. As the temperature drops during daybreak, it retains warmth, maintaining comfort throughout sleep.

The following describes the improvement of skin feel.

In the prior art, as flat double yarn, when used for clothes or bedding, the cloth sticks to the skin when sweating. In addition, because it does not have elasticity, the skin feels hard.

In contrast, the first embodiment, due to the loose B layer and connecting portion 10, creates irregularities. When the convex portions come into contact with the skin, they exert a suitable elastic force, allowing the user to feel a tangible softness. Furthermore, since only the convex portions come into contact with the skin (due to the small contact area), even when sweating, the skin does not feel sticky. Consequently, the skin feel is improved compared to conventional technologies.

Furthermore, when the weft yarn contracts, it is constrained by the connecting portion 10. This results in uneven contraction in the weft direction. Specifically, contraction is smaller in front of and behind the connecting portion 10, while contraction is greater between adjacent connecting portions 10. This creates irregularities in the weft direction, further enhancing the feel to the skin.

The maintenance of lightness will be described below.

The difference between the prior art and the first embodiment is only in the warp yarns 5, 6 of the back layer, which are the same in terms of the surface layer and the weft yarns. In the double-layer yarn, the proportion of the warp yarns 5, 6 is 25% (i.e. one quarter).

Assuming that the feeding speed of the second warp beam is 5.0% faster than that of the first warp beam (the length of the yarn is the weight), the weight of the first embodiment increases by 1.25% (ie, 25%×5%) compared with the prior art.

For the above-mentioned weight increase, when the double-layer gauze fabric is used for clothing or bedding, the user does not feel the difference in weight. In other words, the lightness of the gauze fabric can be maintained.

<Second embodiment>

The structure and manufacturing method of the yarn are described below.

FIG3 is a cross-sectional view of a triple-layer gauze fabric according to a second embodiment of the present invention.

The three-layer yarn fabric includes a surface layer, a middle layer and a back layer.

The warp yarn is supplied from the first warp beam, the weft yarn is inserted, and the tensioned A layer is formed in the middle layer.

The warp yarn is supplied from the second warp beam, the weft yarn is inserted, a relaxed B1 layer is formed on the surface layer, and a relaxed B2 layer is formed on the back layer.

At this time, the feeding speed of the second warp beam is faster than the feeding speed of the first warp beam.

Simultaneously with the formation of layer A and layers B1 and B2, connecting portions 11 and 12 are formed to regularly connect layers A and B1, respectively. The intervals between connecting portions 11 and 12 are the same.

The connecting portion 11 is formed at a position corresponding to the middle position between two adjacent connecting portions 12. The connecting portion 12 is formed at a position corresponding to the middle position between two adjacent connecting portions 11. As a result, the front layer yarn and the back layer yarn are arranged substantially in parallel.

The effects are described below.

The second embodiment is a modified example of the first embodiment. Specifically, layers B are provided on both sides of layer A. This provides the same benefits as the first embodiment. In particular, it further enhances barrier properties, heat retention, and water absorption.

The thickness of the triple-layer fabric formed between the front and back layers is uniform in the warp direction, so the barrier properties, heat retention, water absorption and breathability are also uniform in the warp direction. As a result, the user does not feel uncomfortable.

Furthermore, a gently wavy appearance is created.

<Third embodiment>

The structure and manufacturing method of the yarn are described below.

FIG4 is a cross-sectional view of a triple gauze fabric according to a third embodiment of the present invention.

The third embodiment is the same as the second embodiment in that the three-layer yarn fabric includes a surface yarn, a middle yarn and a back yarn, B layers (B1 layer and B2 layer) are provided on both sides of the A layer, and the connecting parts 11 and 12 are formed.

On the other hand, in the third embodiment, the connecting portion 11 is formed at a position corresponding to the connecting portion 12. The connecting portion 12 is formed at a position corresponding to the connecting portion 11. As a result, the front layer and the back layer are substantially line-symmetrical with respect to the middle layer.

The so-called "corresponding positions" have a width, including an area starting from the same position to a position offset by three weft yarns. The connecting portion 11 and the connecting portion 12 shown in the figure are offset by two weft yarns.

In the case where the connecting portion 11 and the connecting portion 12 are located at the same position and the appearance has a hole, which is undesirable, the weft yarns are shifted by 1 to 3 yarns.

The effects are described below.

The third embodiment is a modification of the first embodiment, similar to the second embodiment, and therefore has the same effects as the first embodiment.

In particular, the thickness of the three-layer yarn fabric formed between the surface layer and the back layer is thicker than that of the second embodiment, thereby further improving the barrier properties, heat retention properties and water absorption properties.

In addition, a clear appearance with concave and convex shapes is formed, so that the appearance design can be appropriately selected.

Other aspects are described below.

The above embodiment is described in detail. The present invention is not limited to the above embodiment. Various modifications and application examples are also included in the present invention without significantly impairing the characteristics of the present invention.

For example, in the second and third embodiments, two A layers may be stacked to form an intermediate layer, thereby forming a four-layer gauze fabric.

In the first to third embodiments, the connecting portion is regularly formed, but may be irregularly formed.

The following is a supplementary explanation.

One of the characteristics of the present invention is to bulk up the multi-layer yarn. The inventors of the present invention originally intended to achieve bulk by drying and shrinking the conventional multi-layer yarn.

However, when bulking is achieved through dry shrinkage, the weight per unit area increases, and the lightness and air permeability that are the characteristics of gauze fabrics cannot be utilized.

Furthermore, because of the uneven shrinkage, the appearance is poor and it is difficult to cut and sew. In other words, it is not suitable for use as a fabric for clothing and bedding.

Therefore, there is a need to explore other methods of bulking multi-layer yarns.

In conventional multi-layer yarn production methods, multiple warp yarns are supplied from a single warp beam. While it is theoretically possible to use more than two warp beams for production, this approach is inefficient. Therefore, from a practical perspective, it is difficult for those skilled in the art to consider using multiple warp beams in yarn production.

The inventors of the present invention came up with the idea of using two or more warp beams while studying how to bulk up multi-layer yarns while maintaining lightness and air permeability. This led to the present invention through trial and error.

Description of Reference Numerals

1, 2: A layer warp yarn

3, 4: A layer weft yarn

5, 6: B layer warp yarn

7, 8: B layer weft yarn

10, 11, 12: Connection

A layer: a layer formed by tensioning the warp yarns

B layer: a layer formed by relaxing the warp yarn

Claims (6)

1. A method for manufacturing multi-layered yarn, comprising: The first warp yarn is supplied from the first warp beam, and the first weft yarn is supplied in a corresponding manner to form a taut layer A yarn; A second warp yarn is supplied from a second warp beam at a faster supply speed than the first warp beam, and a second weft yarn is supplied in accordance with the supply of the second warp yarn, forming a B layer yarn that is looser than the A layer yarn; and A connecting portion is formed that links the A layer yarn and the B layer yarn. By supplying the first weft yarn in correspondence with the supply of the first warp yarn and interweaving the first weft yarn with the first warp yarn, the A layer yarn is made to have a plain weave structure. 2. The method for manufacturing multi-layer yarn according to claim 1, characterized in that the supply speed of the second warp beam is 0.5 to 5.0% faster than the supply speed of the first warp beam. 3. The method for manufacturing multi-layer yarn according to claim 1 or 2, characterized in that the multi-layer yarn comprises multiple layers, the multiple layers including a surface layer, a middle layer, and a back layer. Layer A yarn is formed in the intermediate layer. The B layer yarn is formed in the surface layer and the back layer. 4. The method for manufacturing multi-layer yarn according to claim 3, characterized in that the connecting portion has: The first connecting part regularly connects the surface layer and the intermediate layer; and The second connecting part regularly connects the back layer and the intermediate layer. The first connecting portion is formed at a position corresponding to the middle position of two adjacent second connecting portions. 5. The method for manufacturing multi-layer yarn according to claim 3, characterized in that the connecting portion has: The first connecting part regularly connects the surface layer and the intermediate layer; and The second connecting part regularly connects the back layer and the intermediate layer. The first connecting portion is formed at a position corresponding to the second connecting portion. 6. A multi-layered yarn fabric, manufactured by the method of manufacturing multi-layered yarn according to any one of claims 1 to 5.