TWI846314B - Fabric structure - Google Patents

Abstract

The present invention provides structures of fabric, comprising: a first layer having a first needle-punched density; a second layer located under the first layer and having a second needle-punched density, which is smaller than the first needle-punched density; a third layer located under the second layer; a bonding structure configured to bond and fix the first, second and third layers; and an air-permeable trench structure, the cross-sectional view of which comprises outward protrusions and inward recesses in the first and/or third layer.

Description

Fabric structure

The present invention relates to a fabric structure. Specifically, the present invention relates to a fabric having a breathable groove structure.

With the development of synthetic materials and manufacturing technology, insulation materials with at least one of the functions of heat insulation, sound insulation, and filtering have been widely used in many products. For example, insulation materials can be applied to but not limited to the following products and/or fields according to their characteristics: cold-proof products, industrial/building insulation, sound insulation, etc.

The conventional production method of fabrics used in commercially available insulation materials is to first spray chemical resin on a fiber cotton net or a mixed hot melt cotton, and then put it into a large high-temperature drying box to dry and shape the chemical resin. Such a production method must use a large amount of chemical resin and consume a large amount of fuel to enable boilers or burners to provide high-temperature drying requirements. In addition, the above manufacturing method will produce a large amount of carbon dioxide, waste gas, and waste water pollution. Such a high-temperature, polluted environment has a hidden health concern for production personnel.

In view of the many problems caused by the above-mentioned known production technology, the inventor of this case proposed a fabric with a breathable groove structure and a manufacturing method thereof. This method does not require the use of chemical resins and large high-temperature drying ovens, and can omit the drying process required for the use of resins and hot melt cotton. At the same time, it can combine the advantages of various long-fiber non-woven fabrics/short fibers or long-fiber filaments/film materials. Therefore, the fabric of the present invention can have multi-functions and breathable effects, achieving the environmental protection goals of no chemical resins, energy saving, and zero carbon emissions.

The present invention relates to a fabric structure, comprising: a first layer, comprising first fibers and having a first needle-knot density; a second layer, located below the first layer, comprising second fibers and having a second needle-knot density, wherein the second needle-knot density is less than the first needle-knot density; a third layer, located below the second layer, for reinforcing the isolation of the fabric; a sewing structure for sewing and fixing the first layer, the second layer and the third layer; and a breathable groove structure, in whose cross section, the first layer and/or the third layer has a plurality of outward convex portions and a plurality of inward concave portions.

These and other features of the disclosed embodiments will be described in detail below with reference to the associated drawings.

In the following description, several specific details will be set forth to provide a thorough understanding of the embodiments. The embodiments disclosed herein may be practiced without some or all of these specific details. In other cases, known processing operations are not described in detail to avoid unnecessarily obscuring the disclosed embodiments. Although specific embodiments will be used to illustrate the disclosed embodiments, it should be understood that they are not intended to limit the disclosed embodiments.

FIG. 1 shows a method 100 for manufacturing a breathable fabric according to the present invention, which will be described below in conjunction with FIGS. 2-7 .

FIG2 is a schematic diagram of a fabric 200 according to an embodiment of the present invention. The fabric 200 includes a first layer 202, a second layer 204, and a third layer 206.

First, in step 102 of the manufacturing method 100 of FIG. 1 , a first fiber having a predetermined fiber specification and weight is formed into a fiber web, and then passed through a needle rolling machine for single-sided high-density needle rolling, such as a needle rolling density of 50-300 needles/cm ^2. High-density needle rolling can increase the effect of mutual entanglement between fibers, allowing the originally fluffy and weak fiber web to be entangled together, thereby producing a first layer 202 that is compact, thin, flat, and has structural strength.

In one embodiment, the material of the first fiber can be PP/PET staple fiber, the fiber fineness can be 0.5dtex-15dtex (dtex count), and the length can be 31-100mm. The weight of the fiber web can be 40-160gsm (grams per square meter). In a preferred embodiment, the fineness of the PP/PET staple fiber is 0.5dtex-7dtex.

In step 104 of the manufacturing method 100, the second fiber having a predetermined fiber specification and weight is formed into a fiber web, and then the second fiber is needle-rolled on one side in the reverse direction at a low density (e.g., a needle-rolling density of 3-50 needles/ ^cm2 ) through a needle-rolling machine, or needle-rolling is not performed. Because the needle-rolling density is low or zero at this time, the effect of the fibers being entangled with each other will be less. Therefore, a second layer 204 that is fluffy, elastic, and supportive can be produced, which can achieve the effect of increasing the amount of air. In another embodiment, the second fiber is formed into a fiber web, and then stacked with the first layer 202, and then needle-rolled at a low density through a needle-rolling machine. At this time, the second layer is bonded to the first layer with a low needle rolling density.

In one embodiment, the material of the second fiber can be PP/PET short fiber/long fiber, the fiber fineness can be 0.5dtex-30dtex, and the length can be 31mm-infinite length. The weight of the fiber web can be 10-300gsm. In a preferred embodiment, the fiber fineness is 3dtex-15dtex.

The first layer has a high needle-rolling density, so it has high structural strength and insulation effect. The second layer has a low needle-rolling density, so it retains fiber fluffiness, recovery, support, and has the effect of increasing air volume and heat preservation. Therefore, when the first layer and the second layer are combined together, multiple functional combination advantages can be created.

In addition, the first layer and/or the second layer may be mixed with other different fiber materials to create more functional combination advantages. For example, the mixed fibers may include hollow fibers, elastic fibers, recycled fibers, bicomponent fibers, polylactic acid fibers, natural fibers, etc.

In step 106 of the manufacturing method 100, the first layer 202, the second layer 204 and the third layer 206 are sewn and fixed, thereby forming a fabric 300 having a sewn structure 302 (as shown in FIG. 3), wherein the third layer can be used to strengthen the isolation (e.g., isolation of air, moisture, etc.), heat preservation, and prevent fiber fleece of the fabric of the present invention. In this way, the spaces fixed in each layer allow each fiber layer to move freely in the fixed space. In dynamic state, each fiber layer will float freely due to vibration, thereby increasing air flow or generating heat dissipation. When static, the fiber layer stops moving and each fiber layer has different natural wrinkles or stretches, causing the fiber layer to naturally unfold and become more fluffy, thereby increasing the air volume and heat preservation effect. In this way, the flexibility of the fabric can be increased and the stiffness can be improved. On the contrary, traditional insulation materials fix the fibers into a whole sheet structure, so they cannot achieve the good effect of the present invention.

In one embodiment, the material of the third layer can be PP meltblown nonwoven fabric, and the weight can be 10-100gsm. In other embodiments, the material of the third layer can be PP/PET spunbond nonwoven fabric, waterproof film, metal coating, etc. In one embodiment, the sewing structure is formed by ultrasonic continuous point sewing and has a double diamond checkered wheel pattern. In other embodiments, the sewing and fixing can be performed by hot pressing wheels or high frequencies. In other embodiments, the sewing structure can have a dotted line geometric pattern or an even number pattern. In addition, when sewing and fixing, a fourth layer can be selectively added next to the first layer to enhance the protection of the first layer. The material of the fourth layer may be non-woven fabric, such as long-fiber non-woven fabric, and the weight may be 9-20gsm.

Returning to FIG. 1 , in step 108 , the stitched fabric (e.g., fabric 300 in FIG. 3 ) is passed through a needle rolling device to produce a breathable groove structure. In one example, the stitched fabric is passed through a single-sided needle rolling machine, wherein needles are arranged on the upper or lower needle plate according to the desired spacing to produce a single-sided breathable groove structure 400 (as shown in FIG. 4 ) in the cross section of the fabric. The breathable groove structure 400 includes an outward convex portion 402 and an inward concave portion 404. The needle rolling can intertwine and fix the fibers of the first layer, the second layer, and the third layer with each other in a spaced manner, thereby forming an inward concave portion facing the inside of the fabric, and at the same time, a plurality of needle holes are generated in the inward concave portion. Therefore, the inward concave portion can increase the air permeability of the fabric. At the inward concave portion 404, due to the needle rolling, the fibers of the first layer will enter the second layer and the third layer, and form burrs 406 on the outside of the first layer and the third layer. The outward convex portion that has not been needle rolled maintains a certain fiber fluffy thickness to achieve the effect of heat preservation and isolation. The depth and air permeability of the groove can be adjusted by controlling the needle rolling density. The higher the needle rolling density, the thinner and more solid the fiber layer will be, and the more and larger the needle-punched holes will be, resulting in better air permeability. In the embodiment of Figure 4, the first layer 202 has an outward convex portion and an inward concave portion, and the third layer remains roughly flat. In another embodiment, the third layer may have an outwardly convex portion and an inwardly concave portion, while the first layer remains substantially flat. The total weight of the resulting fabric is approximately 60-400 gsm and the thickness is approximately 3-30 mm.

In another example, a layer of sewn fabric can be passed through a forward/backward needle rolling machine, where the needles are arranged on the upper and lower needle plates according to the desired spacing to produce a double-sided breathable groove structure in the cross-section of the fabric. Unlike the arrangement of ordinary needle plates, the needle hole sizes and hole positions of the force guide plate and the stripping guide plate of such a needle rolling device are different. Specially designed high-density upper and lower needle plates and guide plate mechanisms are required for the manufacture of breathable grooves. The design of the double-sided groove structure can enhance the structural strength, stretchability, flexibility of the fabric, and the effect of air circulation and reflection in the groove, thereby improving the shortcomings of traditional heavy cotton layers that are thick and hard and have poor flexibility.

When using the same forward/reverse needle rolling machine, according to the different needs of the product, the upper and lower needle plates can be arranged with the same width W and the same spacing D (as shown in Figure 5 (a)), so as to form an inward concave portion with the same width on the upper and lower sides (as shown in the ventilation groove structure 600 of Figure 6 (a)). In this way, the ventilation effect on both sides of the fabric can be roughly the same. Alternatively, the upper and lower needle plates can be arranged with different widths and different spacings (as shown in Figure 5 (b) or 5 (c)), so as to form an inward concave portion with different widths on the upper and lower sides (as shown in the ventilation groove structure 610 of Figure 6 (b) or the ventilation groove structure 620 of Figure 6 (c)). In this way, the ventilation effect on both sides of the fabric can be different, one side is warmer, and the other side has better ventilation and heat dissipation. Alternatively, the upper and lower needle plates may be arranged with the same width but different spacings (as shown in FIG. 5( d)) to form outward convex portions with different widths (as shown in the breathable groove structure 630 of FIG. 6( d)). According to the ventilation requirements, the groove structure may be designed to have various widths, so that some parts have more inward concave portions and better breathability, while other parts have fewer inward concave portions and better warmth insulation. Such a design concept of width and spacing may also be applied to embodiments with outward convex portions and inward concave portions on a single side (e.g., the single-sided breathable groove structure 400).

The depth of the inward concave portion will vary depending on the needle rolling density, fiber thickness and material. For example, the width of the inward concave portion of the breathable groove structure can be 2.5-100mm, the width of the outward convex portion can be 5-300mm, and the needle rolling density can be 10-200 needles/ ^cm2 . The above parameters can be adjusted as needed.

In another example, two layers of sewn fabric (e.g., fabric 300) may be stacked up and down and then passed through a forward/backward needle rolling machine. Similarly, needles may be arranged on the upper and lower needle plates according to the desired spacing to produce a double-sided breathable groove structure in the cross section of the double-layer fabric. In yet another example, two layers of sewn fabric may be stacked up and down and then passed through a single-sided needle rolling machine to produce a single-sided breathable groove structure in the cross section of the double-layer fabric.

According to different product requirements, two layers of sewn fabric (e.g., upper fabric and lower fabric) can be stacked in different combinations. In one embodiment, the third layer of the upper fabric (e.g., 206) is stacked on the first layer of the lower fabric (e.g., 202), and then enters the forward/backward needle rolling machine for production, thereby forming a double-layer fabric with a double-sided breathable groove structure, as shown in Figure 7 (a). In another embodiment, the third layer (e.g., 206) of the upper fabric is stacked on the third layer (e.g., 206) of the lower fabric, and then enters the forward/backward needle rolling machine to form a double-layer fabric with a double-sided breathable groove structure, as shown in Figure 7 (b). Similarly, the first layer (e.g., 202) of the upper fabric can be stacked on the first layer (e.g., 202) of the lower fabric, and then produced. In another embodiment, the upper fabric and the lower fabric can be stacked and then passed through a single-sided needle rolling machine to form a double-layer fabric with a single-sided groove structure. The total weight of the formed double-layer fabric is, for example, 120-800 gsm, and the thickness is, for example, 6-60 mm.

In addition, double-layer fabrics can be made of different combinations of materials/specifications/weights to provide diversified applications, choices, designs or functions, and have the advantages of low cost and environmental protection.

FIG8 shows a top view of a fabric 800 having a breathable groove structure. The fabric 800 includes a stitching structure 810 having a double diamond checkered pattern. The fabric 800 also includes a breathable groove structure, including an outward convex portion 820 and a straight inward concave portion 830, the inward concave portion having a plurality of needle-punched holes (schematically represented as 840), which can increase the breathability of the fabric. The size, number, and arrangement of the needle-punched holes are not limited to those shown in the figure. In the embodiment shown in FIG8, the width W1 of the straight inward concave portion is 10 mm, the width W2 of the outward convex portion is 40 mm, and the width of the double diamond grid (the diagonal length of the diamond) is 30 mm and 50 mm, respectively. However, the present invention is not limited thereto and can be modified as needed. In an embodiment using a double-layer fabric, if necessary, continuous dotted double straight line stitches (e.g., by ultrasonic stitching) can be added to the edge 832 of the inward recess 830, and then a ventilation groove can be processed to strengthen the fixation of the double-layer fabric.

Although the above embodiments have been described in detail for the purpose of clarity of understanding, it is apparent that certain changes and modifications may be implemented within the scope of the appended claims. It should be noted that there are many alternative ways to implement the processing methods of the present embodiments. Therefore, the present embodiments should be considered to be illustrative rather than restrictive, and the present embodiments should not be limited to the details set forth herein.

100: Method

102-108: Steps

200: Fabric

202: First floor

204: Second level

206: Third level

300: Fabric

302: Sewing structure

400: Breathable groove structure

402: outward convex part

404: Inward concave

406:Rough Edges

600-630: Breathable groove structure

800: Fabric 800

810:Sewing structure

820: outward convex part

830: Inward concave

832: Edge

840:Acupuncture holes

D: Spacing

W, W1, W2: Width

According to some embodiments of the present invention:

FIG1 is a flow chart showing a method for manufacturing a breathable fabric;

FIG2 shows a schematic cross-sectional view of the fabric;

FIG3 is a schematic cross-sectional view of a fabric having a stitched structure;

FIG4 is a schematic cross-sectional view of a fabric having a breathable groove structure;

FIG5 is a schematic cross-sectional view of the upper and lower needle plates of the forward/backward needle rolling machine;

FIG6 shows a schematic cross-sectional view of a single-layer fabric with different groove configurations;

FIG. 7 shows schematic cross-sectional views of different double-layer fabrics with groove structures; and

FIG. 8 is a schematic top view showing a fabric having a stitched structure and a groove structure.

202: First level

204: Second level

206: The third level

400: Breathable groove structure

402: Outward convex part

404: Inward concave part

406: Rough edges

Claims (16)

A fabric structure includes: a first layer including first fibers and having a first needle roll density; a second layer located below the first layer, the second layer including second fibers and having a second needle roll density, the second needle roll density being less than the first needle roll density; a third layer located below the second layer and used to strengthen the isolation of the fabric; a sewing structure for sewing and fixing the first layer, the second layer and the third layer; and a breathable groove structure, in the cross section of the breathable groove structure, the first layer has a first set of outward convex parts and a first set of inward concave parts, and the third layer has a second set of outward convex parts and a second set of inward concave parts. A fabric structure as claimed in claim 1, wherein at the first set of inwardly facing recesses, the first fiber is present in the second layer and the third layer, and wherein at the second set of inwardly facing recesses, the material of the third layer is present in the second layer and the first layer. A fabric structure as claimed in claim 1, wherein the first group of outward convex portions have the same first width, the first group of inward concave portions have the same second width, the second group of outward convex portions have the same third width, and the second group of inward concave portions have the same fourth width. A fabric structure as claimed in claim 3, wherein the first width is substantially equal to the third width, and the second width is substantially equal to the fourth width. A fabric structure as claimed in claim 3, wherein the first width is not equal to the third width, and the second width is not equal to the fourth width. A fabric structure as claimed in claim 1, wherein the first set of outward protrusions have different widths, and the second set of outward protrusions have different widths. A fabric structure includes: a first layer including first fibers and having a first needle roll density; a second layer located below the first layer, the second layer including second fibers and having a second needle roll density, the second needle roll density being less than the first needle roll density; a third layer located below the second layer and used to strengthen the isolation of the fabric; a sewing structure for sewing and fixing the first layer, the second layer and the third layer; and a breathable groove structure, in the cross section of the breathable groove structure, the first layer or the third layer has a first set of outward convex parts and a first set of inward concave parts. A fabric structure as claimed in claim 7, wherein when the first layer has the first set of outward projections and the first set of inward recesses, at the first set of inward recesses, the first fiber is present in the second layer and the third layer, and when the third layer has the first set of outward projections and the first set of inward recesses, at the first set of inward recesses, the material of the third layer is present in the second layer and the first layer. A fabric structure as claimed in claim 7, wherein the first set of outwardly convex portions have the same first width, and the first set of inwardly concave portions have the same second width. The fabric structure of claim 7, wherein the first layer has the first set of outward convex portions and the first set of inward concave portions, and the fabric structure further comprises: a fourth layer, located below the third layer, the fourth layer comprising the first fiber and having the first needle turn density; a fifth layer, located below the fourth layer, the fifth layer comprising the second fiber and having the second needle turn density; a sixth layer, located below the fifth layer, for reinforcing the isolation of the fabric; and a second sewing structure for sewing and fixing the fourth layer, the fifth layer and the sixth layer, wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions. The fabric structure of claim 7, wherein the first layer has the first set of outward convex portions and the first set of inward concave portions, and the fabric structure further comprises: a fourth layer, located below the third layer, for reinforcing the isolation of the fabric; a fifth layer, located below the fourth layer, the fifth layer comprising the second fiber and having the second needle turn density; a sixth layer, located below the fifth layer, the sixth layer comprising the first fiber and having the first needle turn density; and a second sewing structure, for sewing and fixing the fourth layer, the fifth layer and the sixth layer, wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions. The fabric structure of claim 7, wherein the third layer has the first set of outward convex portions and the first set of inward concave portions, and the fabric structure further comprises: a fourth layer, located above the first layer, the fourth layer comprising the first fiber and having the first needle turn density; a fifth layer, located above the fourth layer, the fifth layer comprising the second fiber and having the second needle turn density; a sixth layer, located above the fifth layer, for reinforcing the isolation of the fabric; and a second sewing structure for sewing and fixing the fourth layer, the fifth layer and the sixth layer, wherein, in the cross-section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions. A fabric structure as claimed in any one of claim items 1 to 12, wherein the fineness of the first fiber is 0.5 dtex-15 dtex, and the fineness of the second fiber is 0.5 dtex-30 dtex. A fabric structure as claimed in any one of claims 1 to 9, wherein the second layer and the first layer are bonded with the second needle density. The fabric structure of claim 10 or 12, wherein the second layer and the first layer are bonded with the second needle-threading density, and the fifth layer and the fourth layer are bonded with the second needle-threading density. The fabric structure of claim 11, wherein the second layer and the first layer are bonded with the second needle-threading density, and the sixth layer and the fifth layer are bonded with the second needle-threading density.

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