JP2006002266A - Three-dimensional woven fabric, metal fiber three-dimensional woven fabric and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve a problem that conventional three-dimensional structure fabrics obtain the three-dimensional structures by the shrinkage of shrinking yarns, but restrict their uses due to the characteristics of the shrinking yarns. <P>SOLUTION: The three-dimensional woven fabric is obtained by shrinking outer woven fabric layers 1, 2 to stand up a standing woven fabric layer 3, and then removing the shrinking yarns. Thereby, the uses of the base yarns are not restricted by the shrinkable fibers. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention provides a three-dimensional woven body, a metal fiber three-dimensional woven body, and a production method thereof, in particular, a shrinkable fiber having a shrinking action by heating or the like to bend a part of the woven fiber to obtain an upright three-dimensional woven body. The present invention relates to improvements in the structure and manufacturing method.

  Conventionally, a three-dimensional woven body has been made by utilizing the heat shrinkability of a fiber, and it has been mainly used as a three-dimensional structure fabric excellent in air permeability, cushioning properties and the like. Patent Document 1 discloses a cushion fabric of this type, which is obtained through a synthetic resin fiber having a large heat shrinkability and a synthetic resin fiber having a smaller heat shrinkage or no heat shrinkability. Alternatively, a woven fabric woven in combination with the background is heat-treated at an appropriate temperature condition, and an elastic portion is formed by bending a synthetic fiber having a small heat shrinkage or no heat shrinkability due to heat shrinkage of the heat shrinkable fiber. As a result, conventionally, cushioning fabrics that can be used in a wide range as clothing, supporters and other sports equipment, medical supplies such as bandages, civil engineering, construction and other industrial materials have been obtained. A three-dimensional structure fabric obtained by further improving such a conventional cushioning fabric is disclosed in Patent Document 2, and a high-shrinkage yarn is used as a warp yarn, and a weft yarn is mainly composed of monofilament, so that it is bent at the time of shrinkage. The three-dimensional structure cloth has a uniform thickness, a uniform thickness, a large repulsive force, a high elasticity, and an excellent breathability, cushioning property, washing durability and the like. According to Patent Document 2, the above-described three-dimensional structure cloth is widely used as a bedding, a cushion, a mat, a shoe insole, or the like.

JP-A-1-321948 JP-A-6-128837

  However, in the conventional three-dimensional weaving body, the heat shrink yarn itself is used as one base fiber of the weaving body, and as a result, there is a problem that the characteristics of the three-dimensional weaving body itself are restricted by the properties of the shrink yarn. .

  That is, polyester-based high-shrinkage yarns are mainly used as conventional shrinkage yarns, but these fibers have heat-shrinkability, but on the other hand, they are not necessarily optimal in other properties required for a three-dimensional weave. There were often no cases.

  In extreme cases, when making a three-dimensional woven body with metal fibers, according to the conventional structure, the polyester-based high-shrinkage yarn constitutes one base fiber of the three-dimensional woven body which is the final product. Even when fibers are used, there is a problem that the desired heat resistance, conductivity, etc. cannot be obtained as a whole three-dimensional weave.

  In this way, when emphasizing the characteristics of the base fiber, there are many cases where the characteristics of the three-dimensional woven fabric and the shrink yarn are incompatible, and for example, when making a three-dimensional woven fabric using only natural materials, polyester-based high-shrink yarn is an obstacle. It was often.

  The above-described metal fiber three-dimensional structure is widely used, for example, as a surface combustion burner mat, a heat insulating material, various filters, a heat insulating muffler for a motorcycle, or a conductive base material for a battery. In particular, the surface combustion burner mat is widely used as a boiler absorption chiller / heater, drying furnace, glass slow cooling path, food heating burner, etc., and has low NOX / CO properties, low noise properties, high radiation efficiency, etc. It is used in a wide range of fields and its demand is extremely large.

  Conventionally, this type of metal fiber three-dimensional structure is composed of a nonwoven fabric laminate of short metal fibers, as shown in the photograph of FIG. This non-woven fabric laminate is a non-woven fabric structure in which short metal fibers are randomly stacked in order to ensure thickness, and the stacking density varies, and if this is used as a mat for a surface combustion burner, the surface temperature There were various problems such as unevenness, metal debris scattering during combustion, generation of defective products on the object to be heated, short durability and high cost.

  Therefore, in the past, there has been a strong demand for such a metal fiber laminate to have a woven three-dimensional structure rather than a non-woven fabric shape.

  The three-dimensional weaving body of the present invention includes a pair of outer weaving layers and a standing weaving layer disposed between the outer weaving layers and at least partially connected to each outer weaving layer. It is woven from twisted yarns with fibers, the standing woven layer is erected between both outer woven layers by the shrinking action of the shrinking fibers, and the shrinking fibers are removed after the erection.

  The base fiber forming the outer woven layer and the standing woven layer is made of metal fiber.

  Further, the shrinkable fiber is characterized by comprising a water-soluble shrinkable fiber.

  The method for producing a three-dimensional weaving body of the present invention includes a step of forming a pair of outer weaving layers by weaving a twisted yarn of a base fiber and a shrink fiber, and a pair of outer weaving layers. Forming a standing weaving layer connected to the outer weaving body, shrinking the shrinking fibers of the outer weaving layer to stand the standing weaving layer to form a three-dimensional weaving body, and removing the shrinking fibers from the three-dimensional weaving body And a step of performing.

  Further, the shrinkable fiber is contracted by heating the outer woven layer.

  In addition, the shrinkable fiber is removed from the three-dimensional weave by dissolving and washing the shrinkable fiber.

  The present invention uses an arbitrary material as a base fiber of a three-dimensional weaving body. For example, a metal fiber is used as a base fiber for a weaving body that requires heat insulation or conductivity, or a natural fiber is used as a base fiber as necessary. After selecting a base fiber arbitrarily according to use or other necessary uses, twisting a shrink fiber to a part of this base fiber, and shrinking the shrink yarn by heating or the like to obtain a desired standing three-dimensional structure, The shrink yarn used for the shrinking action was removed by an appropriate solvent or heating, and only the necessary base fiber was left to obtain a three-dimensional weave.

  Therefore, the obtained three-dimensional weaving body is made only of metal, natural fiber, inorganic fiber or base fiber having desired characteristics, and no shrink yarn component remains, so that it can be used for a desired use as a three-dimensional weaving body. It has the advantage of being able to.

  FIG. 2 shows the basic structure of the three-dimensional woven fabric according to the present invention. In the pair of outer woven layers 1, 2, the outer circle of the double circle indicates the warp and the inner circle thereof is denoted by reference numeral 4. Shows the weft. On the other hand, in the standing weaving layer 3 arranged between the outer weaving layers 1 and 2, the outer ellipse indicates the warp and the inner circle 4 indicates the weft. In the basic structure of the illustrated three-dimensional weaving body, the outer weaving layers 1 and 2 and the standing weaving layer 3 are connected at an appropriate interval, and as is apparent from the figure, the pair of outer weaving layers 1 and 2 contracts. Thus, the standing woven layer 3 is bent upright at an angle of about 45 degrees to provide a desired thickness.

  In order to obtain such a shrinking action of the outer weaving layer, in the present invention, the shrinking fibers are twisted into the base fiber of the outer weaving layer, and the two weft yarns are woven. More specifically, in the case of FIG. 2, a warp of a metal base fiber and a soluble shrinkable fiber is used for the warp of the pair of outer woven layers, while the metal base fiber is used for the warp of the standing woven layer 3. Dissolved non-shrinkable fibers are used. In the present embodiment, the base fiber of the standing woven layer may be only the metal base fiber, but the weaving property when weaving the metal base fiber can be improved by twisting the soluble non-shrinkable fiber.

  The wefts of each layer are composed of woven yarns of metal base fibers and soluble shrinkable fibers, and as described above, the standing woven layer 3 is alternately connected to the outer woven layers 1 and 2 in the warp direction at regular intervals. Weaving with the organization. In this embodiment, the wefts of each layer may be only metal base fibers, but by twisting with soluble shrinkable fibers, it is possible to increase the density when shrinking the metal base fibers in the weft direction.

  Then, after the weaving including the binding is completed, the soluble shrinkable fiber is subjected to a hot water treatment, and the shrinkable yarn is shrunk by heating at this time. , 2 contracts in the warp direction and rises in the direction of the outer weaving layers 1 and 2 to which the upright weaving layers are connected, and also contracts in the weft direction. As a result, a basic structure as shown in FIG. 2 is obtained. Thereafter, the three-dimensional weaving body is subjected to a dissolution washing process using boiling water or a solvent, or is subjected to a heat combustion process. As a result, the soluble shrinkable fibers are removed from the three-dimensional weaving body. As a result, the final three-dimensional weaving body is a three-dimensional weaving body having a composition of almost 100% base fiber, having a thickness due to standing and having a high density in the weft direction.

  As described above, according to the present invention, for example, a water-soluble shrinkable fiber is twisted onto a metal fiber, and this intertwisted yarn is used to weave into a multi-layered structure. A three-dimensional weave can be obtained. Of course, in the multilayer structure, not only a single standing weaving layer is connected between a pair of outer weaving layers, but also such a basic three-layer structure can be sequentially laminated. Further, the outer weaving layer and the standing weaving layer can be laminated. It is also preferable to laminate a plurality of layers alternately with the layers.

  The woven fabric woven in this way has a base fiber, for example, a shrinkage force of a twisted yarn of a metal fiber and a water-soluble shrinkable fiber, a connecting distance between the standing woven layer and an outer woven layer, and a bending resistance of the metal fiber. A three-dimensional weaving body in which the thickness, density and voids can be controlled by the difference, the number of layers of the structure, and the like. The physical performance of these three-dimensional weaves is good in uniform density, heat resistance, heat insulation, uniform combustion, high radiation efficiency, adsorptivity, bulkiness, cushioning properties, etc., and it becomes a three-dimensional weaving body with extremely high functionality.

  FIG. 3 shows the standing change state of the three-dimensional woven fabric according to the present invention. The upper part of FIG. 3 shows a state before the outer weaving layers 1 and 2 are contracted. As is clear from the figure, the standing weaving layer 3 is placed at an appropriate interval between the pair of outer weaving layers 1 and 2. It is connected and arranged at. In this state, when the outer weaving layers 1 and 2 on both sides are contracted by heating or the like, the standing weaving layers are pulled by the outer weaving layers 1 and 2 contracting at the respective connection points 8 and 9, and FIG. As shown in the lower part of FIG. At this time, if the twisted yarn of the base fiber and the shrink fiber is shrunk by 50%, the standing woven layer 3 theoretically rises at an angle of 60 degrees (symbol 7). In FIG. 3, the length of the outer woven layers 1 and 2 indicated by reference numeral 5 is shrunk in half as indicated by reference numeral 6. In practice, the shrinkage force of the twisted yarn of the metal fiber and the shrinkable fiber may not all contribute to the three-dimensional structure of the standing woven layer 3, but the standing woven layer 3 is not limited even if the loss to other yarn stresses is taken into consideration. A rising angle of at least 45 degrees can be secured. Accordingly, the shrinkage rate of the outer weaving layers 1 and 2 is preferably 50% or more, and the rising angle at this time is preferably at least 45 degrees or more with respect to the pressure applied from the outside. In order to have sufficient stress, it is preferable that the rising angle is around 60 degrees.

  The base fiber used for the warp and weft of the three-dimensional weave is a metal fiber such as a heat-resistant stainless steel thread when used for a surface combustion burner that requires heat resistance. Inorganic fibers such as alumina and ceramic fibers are used. The thickness of the three-dimensional woven body is proportional to the shrinkage force of the twisted yarn of the metal fibers and the shrinkable fibers forming the outer woven layer and the distance at which the standing woven layer is in contact with the outer woven layers on both sides. When the thickness is further required, it is preferable to multiplex the standing woven layer. For example, the upright weaving layers are five layers, and the twisted yarns of metal fibers and shrink fibers are used as the upper and lower outer weaving layers and the center layer of the upright weaving layers, and the second and fourth layers of upright weaving. The warp yarn of each layer is made of a twisted yarn of metal fibers and non-shrinkable fibers, and the weft yarn of each layer is composed of a twisted yarn of metal fibers and shrinkable fibers. It is composed of a structure in which the layers and the central standing weaving layer are alternately connected in the warp direction at regular intervals. Further, weaving the fourth standing weaving layer using a structure alternately connected to the opposite outer weaving layer and the central standing weaving layer at a certain interval in the warp direction, after hydrothermal treatment, metal Due to the shrinkage force of the twisted yarn of the fibers and the shrinkable fibers, the second and fourth upright weaving layers rise and a two-layered three-dimensional weave can be obtained.

  In addition, when weaving metal yarns and shrinking yarns to increase the density of weft yarn, weaving a bundle of metal fibers or a strip-shaped metal nonwoven fabric into this weft yarn to provide a finely packed type with thickness and density A metal fiber three-dimensional weave can be obtained. 4 and 5 show the basic structure of such a densely packed three-dimensional woven body, and metal fiber bundles or metal nonwoven fabrics 24 having different densities between the outer woven layers 1 and 2 and the standing woven layer 3, respectively. , 25 are woven into a finely packed metal fiber solid weave.

  In the weaving for forming each weaving layer in the present embodiment, a metal fiber and a water-soluble shrinkable fiber stranded yarn and a metal fiber and a water-soluble non-shrinkable woven yarn are wound around separate beams. Since the weaving machine used uses at least two types of warp, it has a double or more feeding device, and it is necessary to feed with a tension suitable for each warp raw material, so electric feeding that can be controlled independently A device is desirable. Furthermore, the twisted yarn of metal fiber and water-soluble shrinkable fiber has very low elongation, and uneven tension during weaving can cause thickness and poor weaving. It is desirable to have a computer controlled electric delivery control device. Further, the opening device is preferably a dobby machine in order to be able to weave a multi-layered woven structure and to reliably open a variety of warps.

  What is characteristic in the present invention is that after the standing weaving layer 3 is erected by the shrinkage of the outer weaving layers 1 and 2 and the woven body is three-dimensionalized, the shrinking fibers are melted, sintered, or burned. It is to be removed from the three-dimensional weave.

  For this reason, in the present invention, the shrink fibers are made of soluble or combustible shrink fibers such as water-soluble shrink fibers.

  As the above-mentioned water-soluble shrinkable fibers, for example, water-soluble vinylon highly shrinkable yarns are suitable. After the shrinkable yarns are shrunk by heating, the shrinkable fibers can be easily removed by dissolving and washing, so that only the base fibers are obtained. A three-dimensional weave can be obtained.

  In the case of the above-described water-soluble vinylon highly shrinkable yarn, shrinkage occurs in hot water at about 70 ° C., and it can be easily dissolved by washing with boiling water at 100 ° C. Of course, it is also possible to dissolve and remove polyester highly shrinkable yarns, polyurethane yarns, wooly yarns or strong twisted yarns (yarns obtained by solidifying strong twisted yarns with glue or the like) with a predetermined solvent.

  In addition, depending on the type of shrinkable fiber, not only water dissolution or solvent dissolution, but also the shrinkable fiber is preferably scattered by combustion.

  Furthermore, by applying a sintering process to a three-dimensional weave made of almost 100% metal fibers obtained by hydrothermal treatment, the composition of the three-dimensional weave is changed, and the heat-resistant properties, heat insulation, densification, etc. are improved. It can be set as a three-dimensional woven fabric.

  Compared with the nonwoven fabric structure in which the metal fiber three-dimensional woven fabric obtained in this manner is laminated and laminated with random metal short fibers, the lamination density does not vary and the surface temperature does not vary. There is an advantage that metal fiber residue does not scatter during combustion. Moreover, it has excellent durability, a multiaxial shape, a thickness, and a structure in which the vertical and horizontal directions are densified. For this reason, good results can be obtained in uniform density, heat resistance, heat insulation, uniform combustion, high radiation efficiency, adsorptivity, bulkiness, cushion properties, etc., and these performances such as surface combustion burner mats are insufficient in the past. In addition to its use in existing fields, it will expand new fields of use such as insulation and various filters.

  Examples of the present invention will be specifically described below.

  For the warp yarn of the outer woven layer, the metal base fiber is a heat resistant metal yarn having a wire diameter of 0.06 mm and a heat resistant maximum temperature of 1350 ° C. A twisted yarn obtained by twisting a water-soluble vinylon highly shrinkable yarn having a melting temperature of 100 ° C. and a water-soluble vinylon non-shrinkable yarn having a fineness of 110 dtex and a melting temperature of 30 ° C. was used. In order to increase the density of the weft, a twisted yarn of a metal base fiber and a water-soluble shrinkable fiber was used.

  The twisted yarn of metal fiber and water-soluble shrinkable fiber uses a twisting machine with a ring twisting mechanism that can be actively twisted in order to shrink the cross-twisted yarn with a shrinkage force of 50% or more after hydrothermal treatment. One fiber and several water-soluble fibers were twisted together at a twist number of 541 per meter.

  In the present invention, the number of twists per meter is preferably 300 to 800 times.

  In Example 1, each warp is divided into four beams according to the difference in the layers of the multi-layer weaving, the difference in the fineness, and the difference in the yarn type. In order to suppress the occurrence of kinks while applying appropriate tension, bobbin rolling is performed. Warping was carried out by the method, and the warp yarns of each beam were passed through the loom's cocoons in a continuous state, and this was further drawn into the cocoons, and woven into the loom to prepare for weaving.

  As a woven fabric structure, it is a three-layered multilayer structure. The standing woven layer has a flat structure to strengthen the cross-linked structure, and the outer woven layer has a structure point of 1/3 that has fewer structure points than the plain structure in order to improve warp shrinkage. Each layer was partially connected from the connected structure using the oblique structure. Considering the balance of the woven fabric after shrinkage, the composition ratio of the outer woven layer and the standing woven layer was 1: 2, and it was opened and woven by a dobby machine.

  In the present invention, the weave structure can be a cross structure such as a plain structure, an oblique structure and a satin structure, and the composition ratio is preferably 1: 1 to 1: 5.

  The loom used was a one-side rapier loom having a microcomputer-controlled quadruple electric feeding device and a dobby opening device with an electronic dobby controller as shown in FIG. The feeding device was adjusted so as to meet the tension of the twisted yarn of the metal base fiber and the water-soluble shrinkable fiber. At the time of weaving, the woven fabric has a small thickness. However, after the hot water treatment, as shown in the explanatory diagram of FIG. 3, the outer weaving layer shrinks due to the stress of the water-soluble shrinkable fiber having a shrinking force and does not shrink. The weaving layer rises at every bonding, and a multiaxial bulky woven fabric can be obtained. That is, at the time of weaving, the fabric structure shown in the upper part of FIG. 3 is obtained, but after weaving, the standing weaving layer rises and a fabric having a multiaxial structure is obtained. Based on these, the manufactured multi-axial woven fabric could be a multi-axial woven fabric having a high thickness and three-dimensionality as compared with the cross section of a general woven fabric.

  For the wefts of Example 1, two knitted yarns of metal base fibers and water-soluble shrink fibers were used. If the weft density was 30 per cm, the outer weaving layer could be shrunk by 50% or more in the warp direction. As a result, a three-dimensional weave was obtained that was three-dimensional, high-density, and excellent in shape stability and recoverability against compression.

  In the present invention, the fabric density is preferably 10 to 120 per cm.

  When performing the hot water treatment for causing shrinkage for standing in Example 1, the surface shape of the resulting three-dimensional weaving body is obtained by sandwiching the weaving layer 30 between the two plates 20 and 21, as shown in FIG. Smoothness can be imparted. That is, in the initial state of FIG. 7, the gap between the two plates 20 and 21 is larger than the weaving layer 30, and the gap is set substantially equal to the expected final thickness of the three-dimensional weave.

  Therefore, as described above, when the standing weaving layer stands by shrinkage of the shrinking fibers, the thickness of the three-dimensional weave obtained as shown by 30a in FIG. 8 is almost equal to the gap between the two plates 20, 21. Thus, smoothness can be imparted to the surface of the three-dimensional weave in this state.

  In the present invention, the three-dimensional woven body can be used for base fibers of various materials, and not only the metal base fibers shown in the above-described examples, but also other polyesters, nylons, ceramics, aramids, aluminas, carbons or Glass fibers and the like can also be targeted.

  In addition, a wide range of selection is possible for the thickness of the yarn used as the base fiber. For example, in a stainless steel or iron-based metal, a yarn diameter of 10 μm to 1000 μm can be targeted, and a thickness of 10 to 100 μm is preferable among them. Furthermore, what twisted several of these is also suitable.

  When copper or aluminum is used as the metal fiber, the thickness can be 10 to 2000 μm, and a wire diameter of 10 to 200 μm is particularly preferable. Furthermore, what twisted several of these is also suitable.

  Furthermore, in the polyester fiber, it can be widely used up to 1 to 3000 μm, and a wire diameter of 10 to 300 μm is particularly preferable. Furthermore, what twisted several of these is also suitable.

  FIG. 9 shows an example in which the metal fiber three-dimensional woven fabric according to the present invention is used as the surface combustion burner mat 16. When the surface combustion is performed by the mixed gas 26, a good heat insulating effect can be given.

  FIG. 10 shows an example in which the metal fiber three-dimensional woven body 16 is used as a heat insulating material for a muffler that guides an exhaust gas 27 of a motorcycle or the like, and can provide a good heat insulating effect.

  FIG. 11 shows an example of a three-dimensional metal fiber weave produced according to the present invention.

It is a photograph which shows the metal fiber heat insulation structure by the conventional nonwoven fabric. It is explanatory drawing which shows the basic structure of the three-dimensional woven fabric concerning this invention. It is explanatory drawing which shows the standing-up effect | action of the three-dimensional woven fabric concerning this invention. It is a figure which shows the basic structure which shows the state with which the standing woven fabric concerning this invention was filled. It is a figure which shows the other basic structure which shows the state with which the standing woven fabric concerning this invention was filled. It is explanatory drawing which shows an example of the loom with a quadruple feeding apparatus used in the Example of this invention. It is explanatory drawing which shows an example of the hot-water treatment apparatus at the time of manufacturing the three-dimensional woven fabric concerning this invention. In the hot water treatment apparatus shown in FIG. 7, it is explanatory drawing which shows the state by which the three-dimensional woven fabric was obtained. It is explanatory drawing which shows an example which used the three-dimensional woven fabric concerning this invention for the mat | matte for surface combustion burners. It is explanatory drawing which applied the three-dimensional woven fabric concerning this invention to the muffler heat insulating material for motorcycles. It is a photograph which shows an example of the metal fiber solid woven fabric obtained by this invention.

Explanation of symbols

1, 2 Outer weaving layer, 3 Upright weaving layer.

Claims (6)

A pair of outer woven layers, and an upright woven layer disposed between both outer woven layers and at least partially connected to each outer woven layer;
The outer woven layer is woven from a twisted yarn of a base fiber and a shrink fiber, the standing woven layer is erected between the outer woven layers by the shrinking action of the shrink fiber, and the shrink fiber is removed after the erection. Three-dimensional weaving body. The three-dimensional weaving body according to claim 1,
A metal fiber three-dimensional woven body, wherein the base fibers forming the outer woven layer and the standing woven layer are made of metal fibers. In the three-dimensional weaving body according to claim 1 or 2,
A three-dimensional woven fabric and a metal fiber three-dimensional woven fabric, wherein the shrinkable fibers are made of water-soluble shrinkable fibers. Forming a pair of outer woven layers by weaving a twisted yarn of a base fiber and a shrink fiber; and
Forming a standing weaving layer disposed between a pair of outer weaving layers, at least a portion of which is connected to each outer weaving body;
Shrinking the shrinkable fibers of the outer weaving layer and standing up the standing weaving layer to form a three-dimensional weave;
Removing the shrink fibers from the three-dimensional woven fabric;
The manufacturing method of the three-dimensional woven fabric containing this. In the manufacturing method of Claim 4,
A method for producing a three-dimensional woven body, comprising shrinking shrinkage fibers by heating an outer weaving layer. In the manufacturing method of Claim 4,
A method for producing a three-dimensional weaving body, wherein the shrinking fibers are removed from the three-dimensional weaving body by dissolving and washing the shrinking fibers.