JP6932774B2 - Textile products and their manufacturing methods - Google Patents

Description

The present invention relates to a textile product and a method for producing the same, and more particularly to a textile product having an electric / electronic function and a method for producing the same.

Conventionally, various sensors such as a vibration sensor, a temperature sensor, and a pressure sensor are attached to the industrial equipment for the purpose of detecting an abnormality in the industrial equipment. For the industrial equipment (hereinafter referred to as the target product) to be measured for the above purpose, for example, a packaged rectangular sensor (for example, Patent Document 1) is used.

However, the packaged rectangular sensor can be placed if the target product has a flat surface, but if the target product has a complex shape such as a curved surface, the sensor can be easily attached to the target product. There is a problem that measurement is difficult because it cannot be performed.

Japanese Unexamined Patent Publication No. 2008-0387

If the sensor can be attached to a target product having a complicated shape, it is possible to easily measure vibration, temperature, pressure, etc. without being affected by the shape of the target product. Further, it is possible to provide not only a sensor function but also an electric / electronic function including a control function such as temperature control and a communication function.

The present inventors have focused on elastic textile products, and by imparting electrical and electronic functions to textile products, provide textile products and methods for producing the same, which can be applied to target products having complicated shapes. The purpose was.

In order to solve the above problems, the textile product according to the first aspect of the present invention is a textile product manufactured by using a knitted fabric, and the knitted fabric is a knitted thread-like electronic functional member. The electronic functional member includes at least a part thereof, and includes at least two metal wires and an insulating layer that covers the at least two metal wires so that a part of the at least two metal wires is exposed. A thermoplastic resin having a core wire portion including an electronic functional portion electrically conductive to each of the at least two metal wires and a sheath portion including a knitted fabric covering the core wire portion. It is characterized in that the containing yarn is contained in at least a part of the knitted fabric of the electronic functional member, and / or the yarn containing a thermoplastic resin is knitted and woven with the electronic functional member.

According to the first aspect described above, by heating the region including the electronic functional member, the thermoplastic resin existing in the vicinity of the electronic functional member can be melted and solidified. As a result, the region including the electronic functional member can be formed according to the shape of the target product, so that the electronic functional member can be easily attached to the target product having a complicated shape.

Further, the textile product according to the second aspect of the present invention is a textile product manufactured by using a knitted woven fabric, and the knitted woven fabric contains at least a part of a woven thread-like electronic functional member. The electronic functional member includes at least two metal wires, an insulating layer that covers the at least two metal wires so that a part of the at least two metal wires is exposed, and the at least two metal wires. It has a core wire portion including an electronic functional portion electrically conductive to each of the metal wires, and a sheath portion including a knitted fabric covering the core wire portion, and at least the knitted fabric of the electronic functional member. It is characterized in that a solidified thermoplastic resin is contained in a part and / or at least a part around the electronic functional member.

According to the second aspect described above, since the region including the electronic functional member can be molded according to the shape of the target product, the electronic functional member can be easily attached to the target product having a complicated shape. It will be possible.

Further, in the textile product according to the third aspect of the present invention, the core wire is sealed to the outside in the region where the core wire portion is covered with the knitted fabric.

According to the third aspect described above, the water resistance of the sheath portion of the electronic functional member can be increased.

Further, in the textile product according to the fourth aspect of the present invention, the sheath portion covers at least a part of the first covering portion on the core wire portion side made of the knitted fabric and the first covering portion, and the first covering portion. It includes a second covering portion that presses one covering portion toward the core wire portion.

According to the fourth aspect described above, the first covering portion of the electronic functional member can be further brought into close contact with the core wire portion.

Further, in the textile product according to the fifth aspect of the present invention, the second coating portion is a long member spirally wound around the first coating portion.

According to the fifth aspect described above, in the electronic functional member, the first covering portion can be brought into close contact with the core wire portion without damaging the core wire portion.

Further, in the textile product according to the sixth aspect of the present invention, the electronic functional unit includes a chip component, an electronic functional substance-containing film, a battery, an input element, a display element, a sensor, an antenna, a composite element thereof, and an integrated circuit. Selected from the group consisting of.

According to the sixth aspect described above, the size and thickness of the electronic functional member to be mounted can be made smaller, so that the electronic functional member can be made thinner.

Further, in the textile product according to the seventh aspect of the present invention, the core wire portion includes a plurality of the electronic functional parts, and the plurality of electronic functional parts are interconnected by the at least two metal wires to form a circuit. doing.

According to the seventh aspect described above, the electronic functional member can be further miniaturized by using a circuit instead of a component such as a chip.

Further, in the textile product according to the eighth aspect of the present invention, the circuit includes a sensor unit as the electronic functional unit.

According to the eighth aspect described above, the electronic functional member can be used as a measurement tool.

Further, according to the textile product according to the ninth aspect of the present invention, the circuit acts as the electronic function unit, further, a control unit that controls the operation of the sensor unit, and information from the sensor unit to the outside. It includes a communication unit that outputs power, a sensor unit, a control unit, and a power supply unit that supplies electric power to the communication unit.

According to the ninth aspect described above, the electronic functional member can be further miniaturized as a measurement tool.

Further, the invention according to the tenth aspect of the present invention is the method for producing a textile product according to the first aspect, which is a step for producing a knitted woven fabric in which the electric functional member is knitted at least in part. In the step, the electric functional member containing the thermoplastic resin fiber is knitted in at least a part of the knitted fabric, and / or the electronic functional member is made thermoplastic in at least a part region of the knitted fabric. It is characterized by including knitting with resin fibers.

According to the tenth aspect described above, it is possible to provide a textile product having an electro-electronic function capable of forming a region including an electronic functional member according to the shape of the target product.

Further, the invention according to the eleventh aspect of the present invention is the method for producing a textile product according to the fourth aspect, which is a step of producing a knitted woven fabric in which the electric functional member is knitted at least in part. , And / or knitting the electronic functional member with the thermoplastic resin fiber in at least a part of the knitted fabric. It is characterized by including the step of melting and solidifying the thermoplastic resin fiber woven into the knitted fabric.

According to the eleventh aspect described above, by melting and solidifying the thermoplastic resin existing inside or in the vicinity of the electronic functional member, a region including the electronic functional member can be formed according to the shape of the target product. , It is possible to provide a textile product having an electric / electronic function, which can be applied to a target product having a complicated shape.

According to the present invention, it is possible to provide a textile product having an electrical and electronic function, which can be applied to a target product having a complicated shape.

It is a partially broken plan view which shows an example of the structure of the electronic functional member used for the textile product which concerns on Embodiment 1 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. It is a development view which shows an example of the structure of the knitted fabric used for the electronic functional member shown in FIG. It is a schematic plan view which shows an example of the structure of the knitting used for the textile product which concerns on Embodiment 1 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. 4A. It is a schematic plan view which shows another example of the structure of the knitting used for the textile product which concerns on Embodiment 1 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. 5A. It is a schematic plan view which shows another example of the structure of the knitting used for the textile product which concerns on Embodiment 1 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. 6A. It is a partially broken plan view which shows an example of the structure of the electronic functional member used for the textile product which concerns on Embodiment 3 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. 7. It is a partially broken plan view which shows an example of the structure of the electronic functional member used for the textile product which concerns on Embodiment 4 of this invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. FIG. 5 is a partially broken plan view showing an example of the structure of an electronic functional member used in the textile product according to the fifth embodiment of the present invention. It is a schematic vertical sectional view of the electronic functional member shown in FIG. It is a schematic diagram which shows an example of the structure of the electronic functional member used for the textile product of this invention. It is a block diagram which shows an example of the built-in circuit of the electronic functional member used for the textile product which concerns on Embodiment 5 of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings as appropriate.

Embodiment 1
The textile product according to the present embodiment is a textile product manufactured by using a knitted woven fabric, and the knitted woven fabric contains at least a part of a knitted thread-like electronic functional member, and the electronic function The member includes at least two metal wires, an insulating layer that covers the at least two metal wires so that a part of the at least two metal wires is exposed, and each of the at least two metal wires. On the other hand, the knitted fabric having a core wire portion including an electrically conductive electronic functional portion and a sheath portion including a knitted fabric covering the core wire portion, and a yarn containing a thermoplastic resin is the knitted fabric of the electronic functional member. It is characterized in that a thread contained in at least a part of the above and / or containing a thermoplastic resin is knitted with the electronic functional member.

The textile product which is the object of the present invention is a product manufactured by using a knitted woven fabric obtained by being woven or knitted using natural fiber, semi-synthetic fiber, or synthetic fiber yarn. The shape, size, thickness and the like are not particularly limited.

(Electronic functional member)
FIG. 1 is a partially broken plan view of the electronic functional member used in the present embodiment, and FIG. 2 is a vertical sectional view taken along line II-II'of FIG. The electronic functional member 1 has a core wire portion 5 and a sheath portion 20 that covers the core wire portion 5. The core wire portion 5 is electrically connected to each of the first insulating coated metal wire 10 and the second insulating coated metal wire 11 extending in the longitudinal direction thereof, and the first insulating coated metal wire 10 and the second insulating coated metal wire 11. It includes a conductive electronic function unit 12. A knitted fabric 21 is used for the sheath portion 20. Further, a chip component is used for the electronic function unit 12.

As shown in FIG. 2, the first insulating coated metal wire 10 is composed of the metal wire 10a coated by the insulating layer 10b, and the second insulating coated metal wire 11 is composed of the metal wire 11a coated by the insulating layer 11b. .. A part of the insulating layer 10b is removed, and the joint portion 16 is formed so as to be in contact with the exposed metal wire 10a. Further, a part of the insulating layer 11b is removed, and the joint portion 17 is formed so as to be in contact with the exposed metal wire 11a. The electronic function unit 12 has a rectangular shape, and has a pair of external electrodes 12a and 12b that are electronic function units at both ends. By connecting the external electrode 12a to the joint portion 16 and connecting the external electrode 12b to the joint portion 17, the electronic functional portion 12 is electrically connected to the metal wire 10a and the metal wire 11a. In this way, the periphery of the electronic functional unit 12 and the metal wires 10a and 11a that are electrically connected is covered with the knitted fabric 21. The joint portions 16 and 17 may be formed as a structure different from the joint material by plating or the like, but when the insulating layers 10b and 11b are thin, they are joined by a joint material such as solder or a conductive adhesive. Parts 16 and 17 can also be configured. Further, in the region where the core wire portion 5 is covered with the knitted fabric 21, the core wire portion 5 is sealed to the outside.

A copper wire or a nickel wire can be used as the metal wire constituting the core wire portion. Copper wire is preferable. The diameter of the metal wire is not particularly limited as long as it can be knitted on the knitted fabric, but is 1 μm or more and 1 mm or less, preferably 1 μm or more and 0.5 mm or less. Further, the insulating layer prevents the metal wires from coming into direct contact with each other, and a polyurethane resin, an acrylic resin, or a long insulating sheet or tape can be used. In this embodiment, the insulating layer exposes a part of the metal wire in order to ensure electrical continuity with the electronic functional portion. Here, the part of the metal wire may be other than the entire surface of the metal wire, and its area is not particularly limited.

Further, the electronic function unit has the functions of an active element such as a transistor, a diode, and a Pelche element, and a passive element such as a resistor, a capacitor, an inductor, and a thermistor, and has a chip component, an electronic functional substance-containing film, a battery, and an input. Those selected from the group consisting of elements, display elements, sensors, antennas, and composite elements thereof, and integrated circuits can be used.

The passive element may be a chip component or an electronic functional substance-containing film, for example, a thick film resistor, a thin film resistor, a thin film capacitor, or a thin film inductor. Further, the passive element may be an organic material containing an electronic functional substance, a composite material, or a paste material. The electronically functional substance-containing film is heat-treated by applying a solution containing an element raw material, for example, a dielectric raw material, to the surface of a plurality of metal wires by using a known thick film printing method such as spin coating or screen printing. Can be formed with. It is also possible to use an electronic functional substance-containing film patterned by a thin film process. In that case, for example, a lift-off method, vapor deposition, sputtering or the like can be used. In the lift-off method, the resist is applied to the surfaces of a plurality of metal wires, the resist is patterned by lithography, a solution containing the element raw material is applied, and then the resist is peeled off to leave only the pattern of the desired thin film. be able to. Specific examples of the electronic function unit include an NTC thermistor, a PTC thermistor, a Pelche element, and the like. When these elements are used for clothing using electronic functional members, for example, the temperature of clothing can be measured by using an NTC thermistor, the clothing can be warmed by using a PTC thermistor, and the Perche element can be used. You can cool your clothes.

Further, the electronic function unit has a plurality of terminal units for transmitting and receiving signals to and from an external device. Specific examples of the terminal portion include an external electrode, a terminal, an electrode pad, and the like. For example, when the two terminal portions are two terminals, one terminal can be connected to one metal wire and the other terminal can be connected to another metal wire.

Further, the sheath portion includes a knitted fabric that covers the core wire portion, and can be composed of one or more coated portions laminated on the outer periphery of the core wire portion. A knitted fabric can be used for any of the covering portions, but it is preferable to use the knitted fabric for the first covering portion which is on the core wire portion side and at least a part of which is in contact with the core wire portion. In the present embodiment, an example in which the sheath portion is composed of only the first covering portion made of knitted fabric is shown.

A development view of the knitted fabric 21 is shown in FIG. The knitted fabric 21 can form a tubular knitted fabric that covers the periphery of the core wire portion 5 by weft knitting the knitting yarn. Weft knitting is preferable because it can make the stitches finer than warp knitting. Further, in weft knitting, since the stitches are knitted so that the core wire portion in the vertical direction is wound with the knitting yarn, the core wire portion can be tightened relatively strongly by the knitting yarn of the sheath portion, so that the sheath portion is brought into close contact with the core wire portion. be able to.

In this embodiment, the yarn containing the thermoplastic resin is contained in at least a part of the knitted fabric of the electronic functional member, and / or the yarn containing the thermoplastic resin is knitted with the electronic functional member. By heating the region including the electronic functional member, the thermoplastic resin existing in the vicinity of the electronic functional member can be melted and solidified. As a result, the region including the electronic functional member can be formed according to the shape of the target product, so that the electronic functional member can be easily attached to the target product having a complicated shape.

In the case of an electronic functional member in which the yarn containing the above-mentioned thermoplastic resin (hereinafter, also referred to as thermoplastic fiber yarn) is contained in at least a part of the knitted fabric of the electronic functional member, for example, at least a part of the thermoplastic fiber yarn Can be manufactured using the knitting yarn of the knitted fabric. Examples of the thermoplastic resin include polyurethane resin, polyethylene resin, polyester resin, polyamide resin, polypropylene resin and the like. Preferably, a thermoplastic synthetic fiber yarn made of a thermoplastic resin such as a polyethylene resin, a polyester resin, a polyamide resin, or a polypropylene resin can be used. The thickness of the knitting yarn is preferably 33 decitex or more and 250 decitex or less. If it is smaller than 33 decitex, the coverage of the knitted fabric on the core wire portion is not sufficient, and if it is larger than 250 decitex, the knitting yarn is too thick and knitting by a knitting machine becomes difficult. Further, it is also possible to use a plurality of thermoplastic fiber yarns made of thermoplastic resins having different melting points, or composite fiber yarns made of thermoplastic fiber yarns and yarns having no thermoplasticity.

Further, even when the above-mentioned thermoplastic fiber yarn is knitted with an electronic functional member, it is possible to knit using the same thermoplastic fiber yarn as above.

The number of stitches of the same course in the knitted fabric is not particularly limited, but is preferably 2 or more and 8 or less. Since the diameter of the tubular knitted fabric can be reduced, the adhesion of the knitted fabric to the core wire portion can be further improved.

The number of stitches per 1 cm of natural length of the same wales in the knitted fabric is not particularly limited, but is preferably 6 or more and 14 or less. Here, the natural length means a state in which tension or the like is not applied, that is, a state in which the material is naturally placed on a table as it is. When the number of stitches per 1 cm of natural length of the same wales in the knitted fabric is 6 or more, the coverage of the knitted fabric with respect to the core wire portion can be increased. Further, if the number of stitches per 1 cm of natural length of the same wales in the knitted fabric is 14 or less, it is possible to suppress the occurrence of defects due to stitch fogging (tack scratches) of the knitted fabric stitches due to the stitches becoming too fine. ..

Further, when a thermoplastic fiber yarn is used as the knitting yarn of the knitted fabric, the thermoplastic fiber yarn existing in the vicinity of the electronic functional member is melted and solidified as described above, so that the electronic function is matched to the shape of the target product. Not only can the region including the member be formed, but it also has the following effects. That is, by heating and melting the thermoplastic fiber yarn contained in the knitted fabric, the coverage and adhesion to the core wire portion of the knitted fabric solidified after cooling are improved, so that the electronic functional member and the metal wire are washed. It can be protected from moisture derived from sweat and sweat. Further, by heating while pressurizing, the adhesion between the core wire portion and the sheath portion can be further improved. When a composite fiber composed of a plurality of thermoplastic fiber yarns having different melting points is used for the knitting yarn, it is heated to a temperature higher than the melting point of the thermoplastic fiber yarn having a low melting point and lower than the melting point of the thermoplastic fiber yarn having a high melting point. Therefore, the high melting point thermoplastic fiber yarn keeps the state of the knitted fabric, and the durability can be improved by melting only the low melting point thermoplastic fiber yarn.

Further, the electronic functional member can be manufactured by using, for example, the following method. That is, on each of the at least two metal wires, an insulating layer covering the at least two metal wires so that a part of the at least two metal wires is exposed, and the at least two metal wires. The step of forming the sheath portion includes a step of forming a core wire portion including an electrically conductive electronic functional portion and a step of forming a sheath portion covering the core wire portion, and the step of forming the sheath portion is the core wire. It includes at least a step of knitting a knitted fabric around the portion by weft knitting and covering the core wire portion.

The step of forming the core wire portion can further include a step of forming a conductive pattern on a plurality of metal wires and a step of mounting at least one electronic functional portion on the plurality of metal wires. For example, when two metal wires are used, as shown in FIG. 2, a part of the insulating layer on the surface of each metal wire is deleted to expose the surface of the metal wire to form a joint portion that gives a conductive pattern. .. The number of conductive patterns can be selected according to the number of input / output terminals of the electronic functional unit and the number of electronic functional units. Further, as the shape of the conductive pattern, various shapes such as a linear shape, a rectangular shape, a circular shape, and a point shape can be used. When the electronic functional part is mounted on a plurality of metal wires, the electronic functional part is mounted on the plurality of metal wires parallel to each other in the direction perpendicular to the longitudinal direction from the viewpoint of elasticity and durability. It is preferable to do so. Further, when a plurality of electronic functional parts are mounted in the longitudinal direction of the metal wire, a plurality of conductive patterns can be formed at predetermined intervals along the longitudinal direction of the metal wire. The conductive pattern can be formed by a printing method using a conductive paste or an electroplating method.

In the step of covering the core wire portion, a tubular knitted fabric that covers the periphery of the core wire portion can be formed by weft knitting the knitting yarn using a circular knitting machine. As the circular knitting machine, for example, a known circular knitting machine as described in Japanese Patent Application Laid-Open No. 60-193993 can be used.

(Manufacturing method of knitted fabric)
The knitted fabric used in the present embodiment can be manufactured by supplying an electronic functional member to a loom to manufacture a woven fabric, or by supplying an electronic functional member to a knitting machine to manufacture a knitted fabric. That is, the method for producing a knitted fabric used in the present embodiment is a step of producing a knitted fabric in which the electronic functional member is knitted at least in a part, and the step is the step of producing the knitted fabric in at least a part of the knitted fabric. The electronic functional member including the yarn containing the thermoplastic resin of the above is knitted and / or the electronic functional member is knitted with the yarn containing the thermoplastic resin in at least a part region of the knitted fabric. I'm out.

The case of knitting will be described below. An electronic functional member containing a yarn containing a thermoplastic resin (thermoplastic fiber yarn) in the knitting yarn of the knitted fabric is independently fed to the knitting machine (knitting method 1), or a thermoplastic fiber yarn is added to the knitting yarn of the knitted fabric. A combination of an electronic functional member not included and one or more natural fiber yarns, semi-synthetic fiber yarns, synthetic fiber yarns and the like including at least thermoplastic fiber yarns are fed to a knitting machine (knitting method 2) or knitting. An electronic functional member containing a thermoplastic fiber yarn in the ground knitting yarn and one or more natural fiber yarns, a semi-synthetic fiber yarn, and a synthetic fiber yarn containing at least a thermoplastic fiber yarn are combined and fed to a knitting machine. (Knitting method 3). As a method of combining the electronic functional member and the ordinary synthetic fiber yarn, for example, a method of feeding and knitting the electronic functional member and the ordinary synthetic fiber yarn from different yarn yarns of the front yarn, and feeding from the yarn yarn of the same front yarn. There is a method of threading, aligning and knitting. The knitted fabric can be knitted by flat knitting, rib knitting, double-sided knitting, pearl knitting, pile knitting, or the like. Further, the electronic functional member and the ordinary synthetic fiber yarn can be fed from the yarn path of the front yarn and the yarn path of the back yarn, respectively, and plating knitting (attachment knitting) can be used. Further, from an economical point of view, the electronic functional member can be knitted only in a specific necessary part by intarsia knitting (double-sided knitting).

The knitting method 1 is a method in which an electronic functional member containing a thermoplastic fiber yarn is independently fed to the knitting machine in the knitting yarn of the knitted fabric, but a splicing yarn and / or a back yarn can also be used if necessary. .. In that case, natural fiber yarn, semi-synthetic fiber yarn, or synthetic fiber yarn that does not contain thermoplastic fiber yarn can be used as the splicing yarn and the back yarn. This makes it possible to prevent the molten thermoplastic fiber yarn from melting down during the heat treatment.

Next, the knitting method 2 will be described. In the knitting method 2, a splicing thread and / or a backing thread is used. FIG. 4A is a schematic plan view showing an example of the structure of the knitted fabric, and FIG. 4B is a schematic vertical sectional view of the woven fabric. The knitted fabric 70A is knitted by an electronic functional member 71, a back yarn 72, and a splicing yarn 73. The type of yarn used for the knitted fabric constituting the sheath portion of the electronic functional member 71 is not particularly limited, and for example, natural fiber yarn, semi-synthetic fiber yarn, or synthetic fiber yarn that does not contain thermoplastic fiber yarn may be used. can. Further, as the splicing yarn and the back yarn, a natural fiber yarn, a semi-synthetic fiber yarn, or a synthetic fiber yarn containing at least a thermoplastic fiber yarn is used. When one of the splicing yarn and the back yarn contains a thermoplastic fiber yarn, the other yarn is omitted, or as will be described later, a non-melting fiber yarn, for example, a recycled fiber yarn such as rayon, or the above-mentioned A thermoplastic fiber yarn that does not melt at the temperature at which one yarn melts can be used. Further, both the splicing yarn and the backing yarn may include a thermoplastic fiber yarn.

In FIGS. 4A and 4B, a thermoplastic fiber thread is used for the splicing thread 73. The back yarn 72 has a function of preventing the melted splicing yarn 73 from melting down and holding the molten splicing yarn 73 when the knitted fabric is heat-treated. The splicing thread 73 is melted and solidified by heat treatment to increase its rigidity. By heat-treating the region of the knitted fabric including the electronic functional member in a predetermined mold so as to match the shape of the target product, it can be melt-solidified and formed into a predetermined shape.

4A and 4B show an example in which the splicing thread 73 is woven over the entire surface of the knitted fabric 70A, but the splicing thread 73 may be knitted only in a predetermined area. Further, in FIGS. 4A and 4B, an example in which the thermoplastic fiber yarn is used only for the attachment yarn 73 is shown, but the back yarn 72 also uses the thermoplastic fiber yarn that melts at the melting point of the attachment yarn 73 or lower. You may. A planar resin region that covers the periphery of the electronic functional member can be formed.

FIG. 5A is a schematic plan view showing another example of the structure of the knit, and FIG. 5B is a schematic vertical sectional view of the knit. The knitted fabric 70B is knitted by a kanoko knitting with a front yarn 74, a back yarn 72, and a splicing yarn 73 composed of a thermoplastic fiber yarn. An electronic functional member is used for the front thread 74. By using the knitted fabric 70B as a kanoko knit, the splicing yarn 73 can be knitted in a pattern. For example, in the knitted fabric 70B, the region where the electronic functional portion is to be arranged is formed by knitting the splicing yarn 73 and the back yarn 72, and the other portion is formed by knitting the front yarn 74 and the back yarn 72. Further, the front yarn 74 and the auxiliary yarn 73 appear to be interrupted at the end portion 74a and the end portion 73a, but in the actual knitting structure, they are connected side by side by a technique called floating knitting that floats on the back of the knitted fabric. .. That is, the portion where the front yarn 74 is knitted and the auxiliary yarn 73 is passed and the portion where the auxiliary yarn 73 is knitted and the front yarn 74 is passed are arranged and knitted in a kanoko shape.

Further, as shown in FIG. 5B, when the knitted fabric 70B is used as a knitted fabric and the splicing yarn 73 is formed in a mesh shape and heat-treated, the region including the electronic functional portion can be made more difficult to break and crack. Further, by using a transparent splicing thread 73 that does not contain a matte material and not using a back thread 72, or by using a transparent thermoplastic fiber thread that does not contain a matte material for the back thread 72, the electronic functional part can be made. The included area can be made transparent.

FIG. 6A is a schematic plan view showing another example of the structure of the knitted fabric, and FIG. 6B is a schematic vertical sectional view of the woven fabric. The knitted fabric 70C is knitted by a cut boss knitting with a front yarn 74, a back yarn 72, and a splicing yarn 73 composed of a thermoplastic fiber yarn. An electronic functional member is used for the front thread 74. By using the knitted fabric 70C as a cut boss knitted fabric, the splicing yarn 73 can be knitted into a pattern. For example, in the knitted fabric 70C, the region where the electronic functional portion is to be arranged is formed by knitting the splicing yarn 73 and the back yarn 72, and the other portion is formed by knitting the front yarn 74 and the back yarn 72. Further, unlike the kanoko knitting shown in FIG. 5A, each knitting yarn is cut at the portion 75 where the front yarn 74 and the auxiliary yarn 73 overlap.

Next, the knitting method 3 will be described. In the knitting method 3, an electronic functional member containing a thermoplastic fiber yarn and a splicing yarn and / or a back yarn are used as the knitting yarn of the knitted fabric, and the splicing yarn and the back yarn include at least a thermoplastic fiber yarn. , Semi-synthetic fiber yarn, or synthetic fiber yarn is used. When one of the splicing yarn and the back yarn contains a thermoplastic fiber yarn, the other yarn is omitted, or as will be described later, a non-melting fiber yarn, for example, a recycled fiber yarn such as rayon, or the above-mentioned A thermoplastic fiber yarn that does not melt at the temperature at which one yarn melts can be used. Further, both the splicing yarn and the backing yarn may include a thermoplastic fiber yarn.

In addition, the knitted fabric may include at least one power supply unit that is electrically connected to the electronic functional unit. Since the electrical connection between the electronic function unit and the power supply unit can be made by the metal wire constituting the core wire portion, it is not necessary to newly provide a lead wire to connect the electronic function unit and the power supply unit. As a result, the electronic function unit and the power supply unit can be easily connected. The external device that can be electrically connected to the electronic function unit is not limited to the power supply unit, and a signal generator, a transmitter, a receiver, a detection device, a measuring device, a display device, an input device, and the like can also be used.

According to this embodiment, it is possible to provide a textile product having an electrical and electronic function, which can be applied to a target product having a complicated shape. Further, since the electronic functional member to which the electric / electronic function is imparted, the external device such as the power supply unit and the electronic function unit can be electrically connected by the metal wire constituting the core wire portion, so that the external device and the electronic function unit can be electrically connected. You can easily connect to.

Embodiment 2
The textile product according to the present embodiment is a textile product obtained by melting and solidifying the thermoplastic resin contained in the textile product according to the first embodiment, and the textile product according to the first embodiment is a knitting of electronic functional members. The difference is that at least a portion of the ground and / or at least a portion around the electronic functional member contains a solidified thermoplastic resin.

In the textile product according to the present embodiment, at least a part of the knitted fabric of the electronic functional member and / or at least a part around the electronic functional member contains a solidified thermoplastic resin, and the thermoplastic resin is melted. By solidifying, the region including the electronic functional member can be formed according to the shape of the target product. Further, the solidified thermoplastic resin can be fused with other knitting yarns to integrate the electronic functional member with the knitted fabric. As a result, even if the knitted fabric expands and contracts, the electronic functional member does not crack and does not peel off from the knitted fabric. Further, since the rigidity of the region where the electronic functional portion is arranged can be increased to increase the strength and the elongation, it is possible to suppress the deformation of the region and improve the durability of the electronic functional portion.

Hereinafter, the manufacturing method will be described. The method for producing a textile product according to the present embodiment is a step of producing a knitted fabric in which the electronic functional member is knitted at least in a part, and includes the thermoplastic resin in at least a part of the knitted fabric. The step comprising knitting the electronic functional member including a yarn and / or knitting the electronic functional member with a yarn containing the thermoplastic resin in at least a part region of the knitted fabric, and the knitting. It is characterized by including a step of melting and solidifying a yarn containing the above-mentioned thermoplastic resin woven into a woven fabric.

In this manufacturing method, when the electronic functional member is knitted with a yarn containing a thermoplastic resin (thermoplastic fiber yarn), the thermoplastic fiber yarn has a melting point lower than that of other knitting yarns. Or may use a thermoplastic fiber yarn having a melting point equivalent to that of other knitting yarns. When a thermoplastic fiber yarn having a melting point lower than the melting point of another knitting yarn is used, it is preferable to use a thermoplastic fiber yarn having a melting point 30 ° C. or higher, preferably 50 ° C. or higher lower than the melting point of the other knitting yarn. ..

The heating temperature for melting and solidifying the thermoplastic fiber yarn can be appropriately set according to the melting point of the thermoplastic fiber yarn to be used, but exceeds the upper limit of the heat resistant temperature of the electronic functional part included in the electronic functional member. It is necessary not to.

Taking the case of FIG. 4A as an example of the combination of knitting yarns, natural fiber yarns and synthetic fiber yarns having a comparatively high melting point (synthetic fiber yarns having a higher melting point than thermoplastic fiber yarns) are used in the sheath portion of the electronic functional member. Knitted fabrics are knitted using fibers having a relatively high melting point such as nylon or polyurethane (fiber yarns having a higher melting point than thermoplastic fiber yarns) as the back yarns. After knitting, only the region where the electronic functional part is arranged or the entire surface of the knitted fabric is pressurized and heated as necessary to melt and solidify only the thermoplastic fiber yarn having the lowest melting point.

Table 1 shows an example of a combination of a thermoplastic fiber yarn to be melted and another knitting yarn, which is a knitting yarn used for a knitted fabric. Here, the non-molten fiber in Table 1 refers to a fiber other than the thermoplastic fiber to be melted, refers to a fiber used for the sheath portion and the back thread of the electronic functional member, and the molten fiber refers to a thermoplastic fiber to be melted. ..

The combination of the molten fiber and the non-molten fiber is not limited to the range shown in Table 1, and the melting point of the non-molten fiber may be higher than the melting point of the molten fiber by 30 degrees or more.

Embodiment 3
In the present embodiment, as an electronic functional member, the sheath portion is made of knitted fabric and covers at least a part of the first coating portion and the first coating portion which are in contact with the core wire portion, and presses the first coating portion toward the core wire portion. It has the same structure as the textile product of the first embodiment except that the one including the second covering portion is used.

FIG. 7 is a partially broken plan view of the electronic functional member according to the present embodiment, and FIG. 8 is a vertical sectional view taken along line VIII-VIII'of FIG. Hereinafter, the description of the parts common to the first embodiment will be omitted, and only the different parts will be described.

The electronic functional member 2 has a core wire portion 5 and a sheath portion 20 that covers the core wire portion 5. The sheath portion 20 further includes a first covering portion 22 made of knitted fabric and located on the core wire portion 5 side, and a second covering portion 23 wound around the first covering portion 22. The second covering portion 23 can press the first covering portion 22 toward the core wire portion 5 to further bring the first covering portion 22 into close contact with the core wire portion 5.

A long member can be used for the second covering portion. Long members include natural fiber yarns such as cotton, linen and wool, semi-synthetic fiber yarns such as cellulose, synthetic fiber yarns such as nylon, acrylic, polyester and polyurethane, and composite yarns that combine multiple fiber materials. Examples include tapes and strings. By using the long member, the first covering portion can be brought into close contact with the core wire portion without damaging the core wire portion. When a synthetic fiber yarn containing a thermoplastic resin is used for the first coating portion, a synthetic fiber yarn containing a thermoplastic resin can also be used for the second coating portion. By heating and melting the synthetic fiber yarn after coating with the second coating portion, it is possible to further improve the adhesion of the first coating portion to the core wire portion after cooling.

Further, the following example is also possible as a combination of the first covering portion and the second covering portion. For example, when a synthetic fiber yarn containing a thermoplastic resin is used for the first coating portion, a yarn made of the above-mentioned non-melted fiber (hereinafter, referred to as non-melted fiber yarn) can be used for the second coating portion. Further, a non-melted fiber yarn can be used for the first coating portion, and a synthetic fiber yarn containing a thermoplastic resin can be used for the second coating portion. Even in these cases, the adhesion of the first coating portion to the core wire portion can be improved.

The electronic functional member used in the present embodiment can be manufactured by a manufacturing method including a step of spirally winding a long member around the first covering portion after forming the first covering portion. For the second coating portion, for example, by using a known sheath thread winding device described in Japanese Patent Application Laid-Open No. 63-28230, the electronic functional member forming the first coating portion is moved upward or downward. However, the second covering portion can be formed by unwinding the string wound around the bobbin while rotating the bobbin and winding it around the electronic functional member. The winding interval of the second covering portion in the longitudinal direction of the electronic functional member can be adjusted as necessary. By reducing the winding interval (or increasing the number of windings), the adhesion of the first covering portion to the core wire portion can be further improved. Further, by increasing the diameter of the thread constituting the second coating portion, the winding interval can be reduced to further improve the adhesion of the first coating portion to the core wire portion.

According to the present embodiment, in addition to the effect of the first embodiment, by providing the second covering portion, the adhesion of the first covering portion to the core wire portion is further improved, and the durability of the electronic functional member is further improved. Can be improved.

In the present embodiment, an example in which the second covering portion is provided is shown, but a covering portion may be further provided if necessary. For example, the second coating is spirally wound in the longitudinal direction of the electronic functional member, while the second coating is wound on the second coating in the direction opposite to the second coating and intersects the second coating. A covering portion can also be provided. By providing the third covering portion, the adhesion of the first covering portion to the core wire portion can be further improved.

Further, a draw-aligned yarn made of a synthetic fiber yarn containing a thermoplastic resin may be included between the core wire portion and the first coating portion. In this case as well, the adhesion of the first covering portion to the core wire portion can be improved. In this case, when a synthetic fiber yarn containing a thermoplastic resin is used for both the first coating portion and the second coating portion as a combination of the first coating portion and the second coating portion, the first coating portion and the second coating portion When non-melted fiber yarn is used for both, a case where a synthetic fiber yarn containing a thermoplastic resin is used for one of the first coating portion and the second coating portion and a non-melted fiber yarn is used for the other can be mentioned.

Embodiment 4
The textile product according to the present embodiment has the same configuration as the textile product of the first embodiment except that an electronic functional member using an electronic functional substance-containing film is used instead of the chip component as the electronic functional part. ing.

FIG. 9 is a partially broken plan view of the electronic functional member according to the present embodiment, and FIG. 10 is a vertical sectional view taken along line XX'of FIG. Hereinafter, the description of the parts common to the first embodiment will be omitted, and only the different parts will be described.

The electronic functional member 3 has a core wire portion 6 and a sheath portion 20 that covers the core wire portion 6. The core wire portion 6 is electrically conductively arranged with respect to each of the first insulating coated metal wire 10, the second insulating coated metal wire 11, the first insulating coated metal wire 10 and the second insulating coated metal wire 11. It includes an electronic functional unit 13 made of an provided electronic functional substance-containing film.

As described above, the electronic functional substance-containing film is heat-treated by applying a solution containing an element raw material, for example, a dielectric raw material, to the surface of a plurality of metal wires by using a known printing method such as spin coating. Can be formed with. Further, a patterned thin film can also be used. Here, the electronic functional material includes a dielectric material, a conductive material, a magnetic material, a piezoelectric material, a semiconductor material, a pyroelectric material, and the like.

According to the present embodiment, in addition to the effect of the first embodiment, the size and thickness of the electronic functional portion mounted on the metal wire can be flexibly changed by using the electronic functional substance-containing film. It is possible to provide a textile product capable of optimally designing an electronic functional member according to an application.

Embodiment 5
The textile product according to the present embodiment uses a long insulating member as an insulating layer for covering the metal wire, and is formed so as to cover the outer periphery of a plurality of metal wires in a band shape instead of a chip component as an electronic functional part. It has the same configuration as the textile product of the first embodiment except that the electronic functional member using the electronic functional substance-containing film is used.

FIG. 11 is a partially broken plan view of the electronic functional member according to the present embodiment, and FIG. 12 is a vertical sectional view taken along line XII-XII'of FIG. The electronic functional member 4 has a core wire portion 7 and a sheath portion 20 that covers the core wire portion 7. The core wire portion 7 is formed so as to cover the metal wires 10a and 11a extending in the longitudinal direction via the insulating member 15 and the outer periphery of the metal wires 10a and 11a in a band shape, and is electrically conductive with the metal wires 10a and 11a. The electronic functional substance-containing film 14 arranged in the above is included. A knitted fabric 21 is used for the sheath portion 20.

Examples of the insulating member of the electronic functional member used in the present embodiment include a long insulating sheet interposed between the metal wires, an insulating tape attached along the longitudinal direction of the metal wire, and the insulating member in the longitudinal direction of the metal wire. An insulating layer and the like formed along the line can be mentioned. A polyurethane resin, an acrylic resin, or the like can be used for the insulating layer.

As described above, the electronic functional substance-containing film is heat-treated by applying a solution containing an element raw material, for example, a dielectric raw material, to the surface of a plurality of metal wires by using a known printing method such as spin coating. Can be formed with. Further, a patterned thin film element can also be used.

According to the present embodiment, in addition to the effect of the first embodiment, the size and thickness of the electronic functional portion mounted on the metal wire can be flexibly changed by using the electronic functional substance-containing film. It is possible to provide a textile product capable of optimally designing an electronic functional member according to an application.

In the first to fifth embodiments, an example in which one electronic functional unit is provided has been described, but the electronic functional member used in the textile product of the present invention may also include a plurality of electronic functional units. For example, the first electronic functional unit disposed so as to be electrically conductive with respect to each metal wire of the first wiring unit composed of at least two metal wires is different from the first wiring unit. , It may have a second electronic functional part arranged so as to be electrically conductive with respect to each metal wire of the second wiring part composed of at least two metal wires. Similarly, it may have a third wiring unit and a third electronic function unit, a fourth wiring unit and a fourth electronic function unit, a fifth wiring unit and a fifth electronic function unit, and the like. .. The first electronic function unit and the other electronic function units may be different from each other, or all the electronic function units may be the same. For example, a temperature sensor element (for example, an NTC thermistor) can be used for the first electronic function unit, and a heat generating element (for example, a PTC thermistor) can be used for the second electronic function unit.

FIG. 13 is a schematic view showing an example of the structure of the electronic functional member provided with the plurality of electronic functional portions described above, and the sheath portion is omitted. The core wire portion 30 has metal wires 31, 32, 33, 34, 35, 36, each of which is coated with an insulating layer. The two metal wires 31 and 32 form the first wiring portion 37, the other two metal wires 33 and 34 form the second wiring portion 38, and the other two metal wires 35 and 36. Consists of a third wiring unit 39. The first electronic functional portion 41 is joined to the joint portion 31a in which a part of the metal wire 31 is exposed and the joint portion 32a in which a part of the metal wire 32 is exposed. Further, a second electronic functional portion 42 is joined to the joint portion 33a in which a part of the metal wire 33 is exposed and the joint portion 34a in which a part of the metal wire 34 is exposed. Further, a third electronic functional portion 43 is joined to the joint portion 35a in which a part of the metal wire 35 is exposed and the joint portion 36a in which a part of the metal wire 36 is exposed. Although FIG. 13 shows an example in which six metal wires are arranged in parallel, the first to third electronic functional parts can be bundled so as not to come into contact with each other.

Further, the electronic functional member used in the textile product of the present invention may form a circuit by interconnecting a plurality of electronic functional parts with at least two metal wires. This embodiment will be described in more detail in the sixth embodiment below.

Embodiment 6
In the electronic functional member used for the textile product according to the present embodiment, the core wire portion includes a plurality of electronic functional portions, and the plurality of electronic functional portions are interconnected by at least two metal wires to form a circuit. (Hereinafter, the circuit is also referred to as a built-in circuit). FIG. 14 is a block diagram showing an example of the configuration of the built-in circuit. The circuit 60 has a plurality of circuit element portions constituting the circuit, and the circuit element portion corresponds to an electronic function portion. As a circuit element unit, the circuit 60 outputs and inputs a communication signal to the outside, the passive element unit 61, the active element unit 62, the control unit 63 that controls the operation of the passive element unit 61 and the active element unit 62. From the communication unit 64, the power supply unit 65 that supplies power to each unit, the A / D converter unit 66 that A / D-converts the data signal from the passive element unit 61 and outputs it to the control unit 63, and the control unit 63. The D / A converter unit 67 that D / A-converts the control signal of It has a wireless charging unit 69 that outputs the power generated from the radio wave to the power supply unit 65. Further, as an external device, it has a display unit 70 that displays predetermined image information from the control unit 63.

For the passive element unit 61, for example, a sensor can be used as the passive element. In that case, the passive element unit is also referred to as a sensor unit. Examples of the sensor include a temperature sensor, an infrared sensor, a humidity sensor, a sound sensor, an optical sensor, a magnetic sensor, a pressure sensor, an acceleration sensor, a position sensor and the like. Further, for the active element unit 62, for example, a heating element or a vibrating body can be used as the active element. The combination of the passive element and the active element can be variously selected depending on the use of the electronic functional member. For example, by using a temperature sensor for the passive element and a heating element for the active element, it is possible to impart a temperature adjusting function to the electronic functional member. Further, for the power supply unit 65, for example, a capacitor or a secondary battery can be used.

The interconnection of a plurality of electronic functional parts is performed, for example, by arranging a plurality of electronic functional parts along the longitudinal direction of the two metal wires and electrically conducting each electronic functional part with each metal wire. be able to.

The electronic functional member used in the present embodiment can also be knitted by using the same method as that described in the first embodiment. That is, a knitted fabric can be manufactured by supplying an electronic functional member having a built-in circuit to a knitting machine and knitting it as a normal yarn.

According to the present embodiment, in addition to the effect of the first embodiment, by using a circuit instead of a plurality of parts such as chips, it is possible to provide a textile product in which the electronic functional member is made smaller.

In the present embodiment, the circuit element portion other than the passive element portion and the active element portion may not be built in the electronic functional member, and an external device may be used instead. In that case, the external device is held by the knitted fabric, but the electrical connection between the circuit element portion other than the passive element portion and the active element portion and the external device is the metal constituting the core wire portion as described in the first embodiment. It can be done by wire.

Further, the circuit element unit shown in FIG. 14 is an example, and various circuit element units can be used depending on the application.

Although the embodiments of the present invention have been described above, those skilled in the art can understand that they are examples and various modifications can be made within the scope of the present invention. For example, in the third embodiment, an example in which the knitting yarn is spirally wound around the first coating portion as the second coating portion is shown, but the second coating portion may be formed by using a knitted fabric, and plating may be performed. It may be formed by knitting (helix knitting).

According to the present invention, it is possible to provide a textile product having an electrical and electronic function, which can be applied to a target product having a complicated shape.

1,2,3,4 Electronic functional member 5,6,7 Core wire part 10 First insulating coated metal wire 11 Second insulated coated metal wire 10a, 11a Metal wire 10b, 11b Insulation layer 12,13,14 Electronic functional part 12a , 12b External electrode 15 Insulation member 16, 17 Joint part 20 Sheath part 21 Knitted fabric 22 First coating part 23 Second coating part 30 Core wire part 31, 32, 33 Metal wire 34, 35, 36 Metal wire 31a, 32a, 33a Joining part 34a, 35a, 36a Joining part 37 First wiring part 38 Second wiring part 39 Third wiring part 41 First electronic function part 42 Second electronic function part 43 Third electronic function part 60 Circuit 61 Passive element part 62 Active element part 63 Control part 64 Communication part 65 Power supply part 66 A / D converter part 67 D / A converter part 68 Transmission / reception antenna part 69 Wireless charging part 70A, 70B, 70C Knitting 71 Electronic functional member 72 Back thread 73 Addition thread 73a End of attachment thread 74 Front thread 74a End of front thread 75 The part where the front thread and the thermoplastic fiber overlap

Claims (10)

A textile product manufactured using knitted fabrics.
The knitted fabric contains at least a part of a knitted thread-like electronic functional member.
The electronic functional member includes at least two metal wires, an insulating layer that covers the at least two metal wires so that a part of the at least two metal wires is exposed, and the at least two metal wires. It has a core wire portion including an electronic functional portion electrically conductive with respect to each of the above, and a sheath portion including a knitted fabric covering the core wire portion.
In the region where the core wire portion is covered with the knitted fabric, the core wire portion is sealed to the outside.
A textile product in which a yarn containing a thermoplastic resin is contained in at least a part of the knitted fabric of the electronic functional member, and / or a yarn containing a thermoplastic resin is knitted with the electronic functional member. A textile product manufactured using knitted fabrics.
The knitted fabric contains at least a part of a knitted thread-like electronic functional member.
The electronic functional member includes at least two metal wires, an insulating layer that covers the at least two metal wires so that a part of the at least two metal wires is exposed, and the at least two metal wires. It has a core wire portion including an electronic functional portion electrically conductive with respect to each of the above, and a sheath portion including a knitted fabric covering the core wire portion.
In the region where the core wire portion is covered with the knitted fabric, the core wire portion is sealed to the outside.
A textile product containing a solidified thermoplastic resin in at least a part of the knitted fabric of the electronic functional member and / or at least a part around the electronic functional member. The sheath portion covers at least a part of the first coating portion on the core wire portion side and the first coating portion made of the knitted fabric, and presses the first coating portion toward the core wire portion side. The textile product according to claim 1 or 2 , which comprises. The textile product according to claim 3 , wherein the second coating portion is a long member spirally wound around the first coating portion. Any of claims 1 to 4 , wherein the electronic functional unit is selected from a group consisting of a chip component, an electronic functional substance-containing film, a battery, an input element, a display element, a sensor, an antenna, a composite element thereof, and an integrated circuit. The textile product according to item 1. The present invention according to any one of claims 1 to 5 , wherein the core wire portion includes a plurality of the electronic functional portions, and the plurality of electronic functional portions are interconnected by at least two metal wires to form a circuit. Described textile products. The textile product according to claim 6 , wherein the circuit includes a sensor unit as the electronic functional unit. The circuit serves as the electronic function unit, further includes a control unit that controls the operation of the sensor unit, a communication unit that outputs information from the sensor unit to the outside, the sensor unit, the control unit, and the communication unit. 7. The textile product according to claim 7 , further comprising a power supply unit for supplying electric power to the device. The method for producing a textile product according to claim 1.
A step of producing a knitted fabric in which the electronic functional member is knitted at least in a part, and the step is knitting the electronic functional member including a yarn containing the thermoplastic resin in at least a part of the knitted fabric. A method for producing a textile product, which comprises knitting and / or knitting the electronic functional member with a yarn containing the thermoplastic resin in at least a part region of the knitted fabric. The method for producing a textile product according to claim 2.
A step of producing a knitted fabric in which the electronic functional member is knitted at least in part, and knitting the electronic functional member including a yarn containing the thermoplastic resin in at least a part of the knitted fabric, and / Or the step comprising knitting the electronic functional member with the yarn containing the thermoplastic resin in at least a part of the knitted fabric.
A method for producing a textile product, which comprises a step of melting and solidifying a yarn containing the thermoplastic resin woven into the knitted fabric.

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