JPH07238434A - Three-dimensional woven fabric in combination of texture and starting yarns - Google Patents

Abstract

PURPOSE:To obtain woven fabric of three dimensional structure which is excellent in air permeability and cushioning properties by double combinations of a variety of natural and chemical fibers and of a variety of their weaving textures. CONSTITUTION:As the warp, natural fibers such as cotton, linen, wool and chemical fibers such as nylon, polyester or polypropylene are appropriately arranged to constitute, for example, a five-layered texture comprising the first to the fifth layers of plain fabrics in which the warp and the weft completely cross with each other. At the same time, the first layer 1 and the third layer 3 and the third layer and the fifth layer are bonded to each other through the second bonding layer 2 and the fourth bonding layer 4, respectively, by using the weft 9 to cross-stitch or diamond-stitch the bonding points 11. Or multilayer woven fabrics are formed by complicated combination of fineness, rigidity and flexibility of the warp and weft yarns 8, 9 and a variety of textures such as plain fabric, diagonal cloth, binding or core texture. Then, the multilayer woven fabric is heat-treated at elevated temperature and pressure to allow the warp and weft yarns to shrink to give the object woven fabric of three dimensional structure having unique properties.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention comprises a combination of plain weave and twill weave, which is the basic design of a woven fabric, creates a surface design and a back design on the woven fabric, and a core design and a binding design in the central layer. A method of making a multi-layered fabric with a complicated structure, raw yarns such as thick and fine fibers, yarns with different stiffness and softness, natural fibers that do not easily shrink, and chemical fibers that easily shrink and raw materials that do not easily shrink Are arranged in warp / weft yarns at an appropriate ratio to be mixed and woven to form a multi-layered woven fabric, and the woven fabric is heat-treated. Due to the difference in the crossing rate of the composition of the surface layer, the back layer, and the core layer structure, due to the effect of the difference in the tension of the warp / weft, the stress acting on the mixed yarn, the difference in the shrinkage rate / rigid softness of the raw material yarn, etc.
By creating a space between the fabric layers by raising the front and back tissue layers into upper and lower parts, the yarn layer of the core layer structure imparts bulkiness and cushioning properties, and imparts properties such as breathability to the fabric Is. Utilizing these materials, the woven fabric mainly composed of natural fibers is used as a material for clothes such as a table cloth or an insole of shoes, a summer cooler, and bedding. Further, the woven fabric mainly composed of the chemical fiber is a three-dimensional structured woven fabric which can be used in a wide range of fields such as being used as an industrial material such as a filter cloth and a cushioning material for mechanical devices,
The present invention relates to a manufacturing method thereof.

[0002]

2. Description of the Related Art A general woven fabric is a woven fabric in which warp and weft yarns are regularly crossed at right angles and are woven according to a certain rule by a basic woven structure. On the other hand, general double and triple woven fabrics include simple woven fabrics and blistered woven fabrics that have a limited woven fabric structure such as a woven fabric structure. This is a shape that is simply laminated according to the rule for making a general woven structure into a woven structure, and in the case of a blistered woven fabric, a bulge can be partially formed on the ground fabric, but like the three-dimensional woven fabric of the present invention, It is far from having structure and characteristics. This means that a single woven fabric, which is the general woven fabric described above, is formed by simply stacking it in a number of layers, or partially doubled in order to produce unevenness according to the pattern of the woven fabric.
It has been used for a long time to make a woven fabric in the form of a triple weave.

[0003]

The conventional woven fabrics having a lap structure have been limited to a manufacturing method in which limited textures or limited raw material threads are combined. In particular, the blister fabric is made by using a strongly twisted yarn on one side of the double structure and a flat yarn on the other side to partially shrink or partially blister. This method has a drawback that when it is partially wet, it contracts abnormally.
The present invention overcomes the drawbacks of conventional woven fabrics as described above, and takes into consideration the characteristics that conventional woven fabrics do not have, and provides a combination of basic structures and the effect of a woven fabric material having unique properties. By utilizing this technique, a three-dimensional woven fabric having a three-dimensionally strong structure and a wide range of applications, which does not use strong twisted yarn, and a method of manufacturing the woven fabric is developed.

[0004]

[Means for Solving the Problems] In order to achieve the above-mentioned object, the present invention provides a complicated combination of basic structures of fabrics and a complicated combination of differently contracted synthetic fiber yarns having unique properties. A three-dimensional woven fabric, a three-dimensional woven fabric characterized by subjecting this woven fabric to high-pressure heat treatment, and a step of combining a basic structure and a raw yarn, and a shrinkable yarn such as a chemical fiber having a unique property. And a natural fiber which is difficult to shrink as a warp or weft in an appropriate ratio, and a step of subjecting the woven fabric to a high-pressure heat treatment.

[0005]

[Function] The natural fiber and the compound fiber are combined and woven into warp and weft, and the basic structure of the woven fabric is combined by an advanced technique, and the woven fabric is subjected to heat treatment at high temperature and high pressure. A structure or material that has a low shrinkage ratio or a non-shrinkable structure, in which a base fabric is woven using a structure or material yarn with a high shrinkage ratio in one layer or multiple layers of multiple layers By the stress exerted on the interwoven yarn of the woven fabric woven in a multi-layered structure in which another layer or several layers are formed by using the yarn, and after the woven fabric is woven, a high-pressure heat treatment The shrink yarn shrinks and the fabric shrinks 25 percent. By effectively exerting a three-dimensional shape on the woven fabric by these actions and stresses, it is possible to obtain a woven fabric having a three-dimensional structure having excellent functionality such as breathability and cushioning properties.

[0006]

Embodiments of the present invention will be specifically described below with reference to the accompanying drawings. In the invention, as warp yarns, such as polyester yarns and nylon yarns of chemical fibers, which easily shrink rapidly by heat treatment at high pressure and high temperature, and chemical fibers which do not easily shrink,
Alternatively, yarns having a small shrinkage rate even when heat-treated at high pressure and high temperature, such as natural fibers, are used in combination. These warps are selected according to the difference in the crossing ratio of the warp texture, the difference in the fineness, and the difference in the thread type, and four warp yarns are put in the different zone / zone of the different contraction yarns of polyester yarn and nylon yarn, cotton yarn and other yarns. Warp while applying appropriate tension to the beam of
Take up. Warp yarn prepared polyester yarn: nylon yarn: binding cotton yarn: ground yarn are arranged in a ratio of 2: 1: 1: 2 to 2: 1: 1: 4 according to the design, and also in a striped pattern or a random pattern, A large number of warp threads, which are thread ends drawn from each warp thread beam, are arranged in parallel with each other, and the heddle thread is passed through the heddle of the loom in order or skipped.
This is further pulled into the reed several by several and woven into the loom. On the other hand, in the woven structure, one warp diameter of the graph papers shown in FIGS. 3 and 5 represents a floating state of one warp thread, and one weft diameter represents a floating state of one weft thread. Further, a mark point (black square) (16) represents a state in which the warp thread floats and the weft thread sinks, and a point (()) (17) represents a state in which the warp thread sinks and the weft thread floats. FIG. 3 shows the use of an advanced technique in which a basic structure of a woven fabric such as a plain weave (A) a twill weave (B) a satin weave (C) shown in FIG. It is an example in which a multi-layered fabric structure chart was prepared. Based on these, the woven structure of the three-dimensional structure, which is woven, is compared with the cross section of the general woven fabric shown in FIG. 4, and the effects of thickness and three-dimensionality are sought in FIGS. 1, 2, 6, 7, 8, As shown in 9, 10, and 11, three-layer and five-layer fabrics can be woven to obtain a three-dimensional fabric having a high three-dimensionality. As shown in FIG. 1, the woven fabric preferably used in the present invention is composed of a plain weave in which warp yarns and weft yarns are completely interlaced in each layer from the first layer to the fifth layer, as shown in FIG. The second layer is the binding layer, the third layer and the fifth layer are the fourth binding layer, and the weft stitches (11) are arranged in a zigzag or rhombus pattern at intervals of five weft threads. It is a woven fabric structure that is knitted and woven. Considering that the woven fabric after weaving is heat-processed between the surface layer and the core layer, and between the core layer and the back layer, raw material yarns having unique properties to warp yarns are interwoven and processed into a woven fabric. Is carried out to form a tie layer having a function of causing a structural change in the woven fabric. The composition of the five woven layers and the arrangement and the knotting method of the knotting points (11), the effect of the knitting structure, the difference in the raw / thin fine-thickness yarns and the soft-softness yarns are combined in a complicated manner. Then, a woven fabric having a three-dimensional structure is constituted by the effect of the stress exerted on the interwoven yarn and the effect of the difference in shrinkage ratio of the raw yarn. Using the third layer as the core layer as the base fabric, the second and fourth layers of the connecting layer are actuated from the center layer (core layer) to the first layer of the front layer and the fifth layer of the back layer. As shown in the cross-sectional view of FIG. 2, the second layer and the fourth layer of the woven fabric have a bulkiness compared to the general woven fabric (FIG. 4) by changing the structure of each woven fabric and adding thickness to the woven fabric. This is an example in which a three-dimensional structure woven fabric having a woven structure in which the tie layer has the characteristic of being capable of causing the action of the rising woven fabric layer (12). Woven cloth after the implementation,
Due to the stress exerted on the interwoven yarn of the chemical fiber having the unique property, the bulkiness is increased, and the three-dimensional effect is obtained on the woven fabric. Due to the difference in the different shrinkage of the chemical fibers with properties, the difference between the shrinkable yarn and the difficult-to-shrink yarn can exert the effect of bulkiness on the fabric, and it is possible to obtain a fabric with an excellent three-dimensional structure having thickness and bulkiness. it can. These woven fabrics have been evaluated as attractive for use in clothing for summer as a cooling material, and as an outer material for shoes and insoles. A slightly sparsely woven material can be used as an industrial filter cloth or cushion material.

Example 1 The warp yarn is a combination of natural fiber cotton yarn 20 / 2S, chemical fiber polyester shrink yarn 200D × 2 (shrinkage rate, about 25%) and chemical fiber nylon monofilament yarn 1100D. Cotton yarn: polyester shrink Threads: Nylon monofilament threads are arranged in a 3: 2: 1 arrangement, and the warp threads are divided into 4 beams, warped and wound, and then 12 healds are passed through to prepare warp threads and other weaving preparations. Carried out. The warp yarn arrangement and the fabric composition are the same as those of the former and the latter in consideration of the feel of the woven fabric, using chemical fibers for the front and back layers and natural fibers for the core layer, and the former and the latter considering the breathability of the fabric. Examples were also carried out. As for the woven structure, 12 healds were drawn in order, and the woven fabric was mainly composed of the Mihara structure (FIG. 5) and the triple structure. Weaving was carried out by a method in which a knotting yarn was added to this to form a structure. The front and back layers and the core layer are plain weave, and the binding layer (thread) is a structure that connects the front layer and the core layer and the core layer and the back layer. As shown in the cross-sectional views of FIG. 6 and the image cross-sectional views of FIGS. 7 and 8, one layer and three layers have a structure that completely intersects with the weft thread, and the binding thread is a warp thread that connects each layer and each layer. It is an example of three types of weaving composed of warp yarns that play a role of raising the first layer (front layer), the second layer (core layer), and the third layer (back layer). It is shown. The front layer and the back layer are completely interwoven with warp and weft to form a woven layer. The core layer has a structure in which the warps and wefts of four wefts are interlaced. In addition, 26 weft yarns are woven fabrics having a partially triple structure with a structure in which warp and weft do not cross each other.
Make a connecting point (11) on the third layer. After the weaving, the stress acting on the mixed yarn after the weaving, the effect of the different shrinkage yarn and the heat treatment make it possible to form a state in which the binding yarn is raised in the front and back layers of the first and third layers from the second layer as the base fabric. It is an example of a three-dimensional structure textile. The structure shown in FIG. 7 is mainly composed of three layers, but the warp yarns to be knotted are knotted at the knotting point (11) for every few weft yarns for the first layer (front layer) and the third layer (back layer). However, it is an example of a three-dimensional structure woven fabric having a long binding yarn structure that rises due to a structural change caused by stress applied to the interwoven yarn or heat treatment in the state of the binding layer (12) indicated by the broken line. The configuration of FIG. 8 is
~ Indicates from the first layer (front layer) to the fourth layer (back layer) of the woven fabric, and the first and fourth layers are completely warped to form a woven fabric structure in which the wefts are interlaced, and the second layer (core layer) , The third layer (core layer) is partially organized at intervals of several weft threads. The woven fabric is constructed by connecting the front and back layers with the connecting point (11), and the broken line (13) and the two-dot chain line ().
The knotted warp yarns in the state of 13) pass through the second layer and the third layer, and the state of the broken line ▲ 13 ▼ is from the first layer to the fourth layer, and conversely, the state of the chain double-dashed line ▲ 13 is from the fourth layer. By alternately composing up to the first layer and forming a bridge-like structure, the three-dimensional effect is effectively produced. Thick dashed line ▲ 14
▼ shows a state of a complicated structure in which the wavy line layer and the two-dot chain line of the binding yarn (13) merge and become a single layer, and become a branch point where the first layer direction and the fourth layer direction intersect. It is an example of a three-dimensional structure woven fabric that effectively increases bulkiness. The woven fabric after the weaving has a bulkiness effect due to the stress exerted on the interwoven yarn of the chemical fiber having the peculiar property, and further the heat treatment at high temperature and high pressure at 130 ° C. for 30 minutes makes the peculiar property Due to the difference in the different shrinkage of the chemical fibers with the difference between the shrinkable yarn and the difficult-to-shrink yarn, the woven fabric can exert the effect of bulkiness and can obtain a thick fabric having an excellent three-dimensional structure. These woven fabrics have been evaluated as attractive for clothing as summer clothes, for dressing on shoes and as insoles. A slightly sparsely woven material can be used as an industrial filter cloth or cushion material.

Example 2 The warp yarn is divided into four beams according to the difference in fineness and the difference in the tissue ratio, and the natural fiber cotton yarn 20 / 2S, the chemical fiber Polyester shrink yarn 200D × 2, and the nylon monofilament 1100D. Arranged in a ratio of 5: 2: 1, 16
The preparation for carrying out the pull-in by passing through the sheets was completed, the warp beam was hung on the loom, and the weft was made of cotton, and the weaving was performed while adjusting the warp tension. On the other hand, the structure of the woven fabric is mainly a five-layer weave structure based on the fact that the warp yarns are 5: 2: 1 cotton yarns: polyester yarns: nylon yarns, and 16 healds are pulled in by skipping. Carried out. In addition to the surface layer, the core layer, and the back layer, the binding layer has a warp and weft, and a woven fabric layer having a completely textured and hard texture is added to form a quintuplet structure. The bonding layer has a layout of bonding points in order to effectively three-dimensionalize the front and back layers with the core layer as the base fabric, and the layers that respectively configure the fabric, while creating a fabric structure structure for the own layer. Bonding is performed in a rhombic or zigzag manner on each layer, and the shapes and arrangements of the bonding layers and the bonding points are adjusted, as shown in FIG.
A fabric having a shape as shown in the image sectional views of 10 and 11 was carried out. Taking into account the seven-layered structure among them, the five-layered structure and the seven-layered structure are mixed to enhance the three-dimensional structure effect, and the structure is made in a complicated form as shown in the cross-sectional view of the fabric image of FIG. It is an example of weaving of three types of three-dimensional structure fabric. In the structure of FIG. 9, the connecting layer (12) of the structure in which the warp and weft yarns of the second and fourth layers of the five-layer structure are completely crossed is the surface layer at the connecting point (11). (First layer), core layer (third layer) and back layer (fifth layer)
Each of the examples is a three-dimensional structure woven fabric showing a large three-dimensional effect by connecting in a zigzag or rhomboid pattern at a ratio of vertical and horizontal intervals. The configuration of FIG.
In the figure, -shows the first layer (front layer) to the seventh layer (back layer) of the woven fabric. The first layer, the fourth layer (core layer) and the seventh layer form a woven structure in which the warp and weft threads are completely crossed. Second layer, third layer (connecting layer ▲ 1
2 ▼) and the 5th and 6th layers (bonding layer ▲ 12 ▼) are the confluent layer ▲ 15 ▼ and the 5th and 6th layer of the second layer and the third layer of the woven layer according to the ratio of several weft threads. Confluence layer of fabric layers of ▲ 15 ▼
And, if necessary, separate two or three woven fabric layers separately. This woven layer comprises a binding layer (12) and a zigzag or rhombus-like surface layer (first layer) due to the binding point (11).
And the core layer (fourth layer) in the fabric layer, and the core layer (fourth layer)
And the fabric layer of the back layer (seventh layer). After that, a woven fabric layer of a seven-fold weave is formed again to form a binding layer (12). In the entire fabric structure, the two layers are separated from the second layer and the third layer, and the fifth layer and the sixth layer are merged to form a single-layered fabric, as shown in the confluent layer (15). It is an example of a three-dimensional structure woven fabric having a three-dimensional structure and a three-fold woven structure which is partially formed depending on a part to be formed and has a complicated structure to enhance a three-dimensional effect. In the structure of FIG. 11, the second and fourth connecting layers (12), in which the warp and weft threads are completely crossed to form a texture, are directly connected to each other by the connecting points (11). (First layer), core layer (third layer), and back layer (fifth layer) are connected in a zigzag or rhombus pattern at intervals of several vertical and horizontal lines. is there. The weft yarn is a core weft yarn (10) that is added in order to add thickness and bulkiness to the woven fabric and to add hardness to the woven fabric. This is an example of a three-dimensional structure woven fabric in which a cored structure is added to a complicatedly intersecting structure from the front layer to the back layer in order to effectively enhance the three-dimensional effect. Woven fabrics are bulky due to the stress exerted on the interwoven yarns by using natural / chemical fibers woven at the time of weaving, thick / fine fibers and raw yarns with different stiffness / softness. A three-dimensional fabric having the effect of was obtained. Furthermore, 130 ℃
Heat treatment for 30 minutes at high temperature and high pressure causes a difference in heterogeneous shrinkage of chemical fibers with unique properties. Due to the difference between shrinkable and difficult-to-shrink yarns, the effect of bulkiness on the fabric can be demonstrated It is possible to obtain a woven fabric having a three-dimensional structure excellent in bulkiness. The fabric of the example is applied to the place where the impact of mechanical equipment is severe, by applying the cushioning property of the space formed in the middle layer of the fabric for industrial use, such as for summer refreshing, shoe outerwear and insole, etc. Used for buffer function for buffering. Further, it is possible to inject a coagulant or the like into the space to harden the shape and use it as a bearing stand.

[0009]

As described above, the present invention is composed of chemical fibers, cotton threads, etc., and is characterized by combining the unique properties of abundant and inexpensive chemical fibers and cotton threads. A woven fabric that takes advantage of this characteristic has an effect of making the woven structure into a three-dimensional structure due to the stress acting on the interwoven yarn such as the difference between the thick and thin counts and the bending resistance. Further, the degree of shrinkage of the chemical fiber is larger than that of the cotton yarn, and there is a difference in the shrinkage rate among the chemical fibers. It is possible to provide a woven fabric having a functionally excellent three-dimensional structure by using these materials and subjecting the woven fabric to high-temperature and high-pressure heat treatment after weaving to give a woven fabric three-dimensionality. . Furthermore, the effect of stabilizing and retaining the shape and form of the woven fabric can be obtained by performing heat treatment. The physical performance of these fabrics is
A highly functional woven fabric that has high performance in terms of breathability and hygroscopicity. From the above effects, it is expected to be used for clothing as summer clothes, bedding, and other applications such as cushions, shoe covers and insoles. On the other hand, as an industrial material, it can be used in a wide range of fields such as filter cloths, buffer materials for high impact parts of machinery and equipment, and pouring solidified material into the space of the fabric to solidify and use it for bearings. It is expected that there will be some, and it can be expected to significantly expand the applications.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a three-dimensional woven fabric having a warp yarn longitudinal section and a weft yarn transverse section, which are mainly composed of a five-fold weave design.

FIG. 2 is a cross-sectional view of a three-dimensional structure fabric having a warp yarn longitudinal cross section and a weft yarn cross section in which a woven fabric mainly having a five-fold weave structure is changed in shape to be three-dimensionalized.

FIG. 3 is an organization chart showing a state of warp and weft of a three-dimensional structure fabric.

FIG. 4 is a fabric cross-sectional view of a warp yarn cross-section and a weft yarn cross-section of a general fabric.

FIG. 5 is a structural diagram showing the floating / wetting state of warp / weft of general fabric.

FIG. 6 is a cross-sectional view of a three-dimensional woven fabric having a warp yarn longitudinal cross section and a weft yarn transverse cross section in which a woven fabric mainly composed of a triple weave structure is changed in shape to be three-dimensional.

FIG. 7 is an image cross-sectional view of a three-dimensional structure fabric mainly composed of a triple weave structure.

FIG. 8 is an image cross-sectional view of a three-dimensionally woven three-dimensionally structured fabric mainly composed of a triple weave structure.

FIG. 9 is an image cross-sectional view of a three-dimensional structure fabric mainly composed of a five-fold weave design.

FIG. 10 is an image cross-sectional view of a three-dimensional woven fabric mainly composed of a five-fold weave and partially having a seven-fold weave.

FIG. 11 is an image cross-sectional view of a three-dimensional structure fabric mainly composed of a five-fold weave structure and containing a core weft.

[Explanation of symbols] First layer of fabric layer Second layer of fabric layer Third layer of fabric layer Fourth layer of fabric layer Fifth layer of fabric layer Sixth layer of fabric layer Seventh layer of fabric layer Weft ▲ 10 ▼ Core weft ▲ 11 ▼ Bonding point ▲ 12 ▼ Bonding layer ▲ 13 ▼ Bonding yarn ▲ 14 ▼ Bonding yarn confluence point ▲ 15 ▼ Fabric layer confluence layer ▲ 16 ▼ Warp point of warp yarn ▲ 17 ▼ For warp yarn Sinking point (A) Plain weave (B) Twill weave (C) Satin weave

Claims (2)

[Claims] 1. A combination of a woven fabric structure that forms the front and back surfaces of a woven fabric and a core layer, and a multi-layered woven fabric is formed by a binding fabric to the combination of the woven fabric structure, and a chemical fiber having a unique property with a difference in shrinkage ratio. A three-dimensional fabric characterized by changing the fabric structure and knitting by combining the yarns and applying stress to the mixed yarns of the woven fabric or heat treatment of the woven fabric after weaving to make a fabric with a three-dimensional structure. Structural fabric. 2. A plain weave, a twill weave, a variable weave and a knot weave.
A method of constructing a woven fabric by appropriately combining woven fabrics such as core fabrics, and different shrinkage of natural fibers (cotton, hemp, wool, etc.) and chemical fibers (nylon, polyester, polypropylene yarns, etc.), stiffness yarns, etc. A method of appropriately arranging textile material yarns having unique properties and interwoven, and the effect of the woven structure,
Fabrication of a three-dimensional structure characterized by having a method of forming a three-dimensional structure of a fabric using a unique property such as a difference in shrinkage ratio of raw yarns and a method of subjecting this to a heat treatment at high temperature and high pressure. Method.