Classifications

• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
  • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
  • A41D27/00—Details of garments or of their making
  • A41D27/24—Hems; Seams
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
  • A41D31/00—Materials specially adapted for outerwear
  • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
  • A41D31/10—Impermeable to liquids, e.g. waterproof; Liquid-repellent
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41H—APPLIANCES OR METHODS FOR MAKING CLOTHES, e.g. FOR DRESS-MAKING OR FOR TAILORING, NOT OTHERWISE PROVIDED FOR
  • A41H43/00—Other methods, machines or appliances
  • A41H43/04—Joining garment parts or blanks by gluing or welding ; Gluing presses
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/36—Cored or coated yarns or threads
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/38—Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/46—Sewing-cottons or the like
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05B—SEWING
  • D05B93/00—Stitches; Stitch seams
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06H—MARKING, INSPECTING, SEAMING OR SEVERING TEXTILE MATERIALS
  • D06H5/00—Seaming textile materials

Definitions

• the present invention relates to heat-sealable sewing thread, a waterproof joint structure using heat-sealable sewing thread, an end fixing structure using heat-sealable sewing thread, and methods for manufacturing these.
• the objective of the present invention is to provide a heat-sealable sewing thread that provides strong seams and allows for stable sewing.
• the present invention provides a heat-sealable sewing thread that provides strong seams and allows for stable sewing.
• FIG. 3 is a schematic diagram showing a sewing needle and a thread eye.
• 11 is a cross-sectional view schematically showing a cross section taken along line XVI-XVI in FIG. 10. Scanning electron microscope image of the adhesive lock thread area and its surroundings.
• 10 is a cross-sectional view schematically showing a cross section taken along line XVIII-XVIII in FIG. 8.
• FIG. 10 is a partial cross-sectional view of the end stitching in the first modified example.
• FIG. 10 is a cross-sectional view of an end sewn portion in a second modified example.
• FIG. 10 is a cross-sectional view of an end sewn portion in a third modified example.
• FIG. 10 is a plan view of a stitched portion in a fourth modified example.
• FIG. 10 is a plan view of a stitched portion in a fourth modified example.
• FIG. 1 is an enlarged schematic view showing a single heat-sealable sewing thread S1 according to one embodiment of the present invention.
• the sewing thread S1 is made of a thread including first and second heat-sealable yarns Sb and Sc.
• the heat-sealable sewing thread S1 is formed by spirally winding first and second heat-sealable threads Sb, Sc, each containing a heat-sealable component, around a base thread Sa, which does not contain a heat-sealable component.
• the base thread Sa is formed, for example, from a polyester two-ply yarn or a three-ply twisted yarn (e.g., a filament yarn having a thickness of 75 dtex to 80 dtex, formed by a three-ply twist of 24 single filament yarns).
• the twist numbers of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to between 450 turns/m and 550 turns/m, and in this embodiment, the twist number is set to approximately 500 turns/m.
• the twist angle ⁇ of the lower heat-sealed yarn Sb may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• the twist angle ⁇ of the upper heat-sealed yarn Sc may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• each twist angle ⁇ , ⁇ is the angle between the axis X1 of the base yarn Sa and the lower heat-sealed yarn Sb or the upper heat-sealed yarn Sc.
• FIG. 2 is an enlarged cross-sectional view showing the area around the eye 61 of the sewing needle 6 through which the heat-sealable sewing thread S1 is inserted.
• the eye 61 of the sewing needle 6 is generally elliptical, having a major axis 61a and a minor axis 61b.
• the width d1 of the sewing needle 6 is preferably small to reduce the diameter d of the needle eye created when sewing two pieces of fabric.
• the eye 61 is preferably large relative to the width d1 of the sewing needle 6.
• the eye 61 may be a size 14 sewing machine needle manufactured by Organ Needle Co., Ltd., in which the length of the major axis 61a is set to approximately 0.8 mm and the length of the minor axis 61b is set to approximately 0.3 mm.
• the width d1 of the sewing needle 6 refers to the width of the portion of the sewing needle 6 where the minor axis 61b is located.
• the diameter Z1 of the heat-sealable sewing thread S1 may be set to between 0.35 and 0.9 times the length Z of the major axis 61a of the thread eye 61 of the sewing needle 6, and is set to, for example, 0.5 times.
• Figure 3 shows an end fixing structure 1 in which a heat-sealable sewing thread S1 according to one embodiment of the present invention is used as a locking thread to fix the ends of two pieces of fabric 2, 3.
• the pitch P1 of each of the first and second loops L1, L2 may be set to between 0.5 mm and 3.0 mm, and in this embodiment is set to 1.0 mm or 2.0 mm.
• the pitch P1 of the first and second loops L1, L2 corresponds to the feed stitch pitch of a lockstitch machine and is the longitudinal separation distance between adjacent first and second loops L1, L2.
• the pitch P1 is 2.0 mm
• the number of stitches is 14 stitches per 3 cm
• the pitch P1 is 3.0 mm
• the number of stitches is 22 stitches per 3 cm.
• the number of stitches is the number of perforations per 3 cm.
• the width W1 of each of the first and second loops L1, L2 may be set to between 5 mm and 8 mm, for example, 6 mm.
• the width W1 of each of the first and second loops L1, L2 corresponds to the stitch width of the overlock machine and is the distance from the edge 2a, 3a of the first fabric 2 and the second fabric 3 to the end L11, L21 on the opposite edge 2a, 3a side of each of the first and second loops L1, L2.
• Figure 6 is a cross-sectional schematic diagram taken along line VI-VI in Figure 3, showing the seam 4 and the end adhesive portion 5.
• the end adhesive portion 5 is formed by first stitching the overlocked first end 21 and second end 31 together, then folding the second fabric 3 in the direction opposite to the stretch direction of the first fabric 2, and then turning the first end 21 and second end 31 over to one side and heat-sealing them to the back surface 3b of the second fabric 3 at 100 to 200 degrees.
• the heat-sealed threads Sb and Sc of the locking thread S1 are melted by heat and then cooled, bonding the first end portion 21 and the second end portion 31 to the main body portion 30.
• the end adhesive portion 5 distributes adhesive 91 remaining after the heat-sealed threads Sb and Sc of the locking thread S1 have melted. More specifically, as shown in FIG. 7, the first end portion 21 and the second end portion 31 remaining after the heat-sealed threads Sb and Sc have been heat-melted are sewn together with the base thread Sa of the locking thread S1 and bonded together with the heat-sealed threads Sb and Sc.
• the end adhesive portion 5 is the portion where the first end portion 21 and the second end portion 31 are bonded to the main body portion 30 of the second fabric 3 by adhesive 91 distributed in the bonded portion locking thread portion 51 along the locking thread S1.
• the end adhesive portion 5 is arranged between the edges 2a, 3a of the first fabric 2 and the second fabric 3 and the ends L11, L21 of the first loop L1 and the second loop L2.
• the width of the end adhesive portion 5 roughly matches the width W1 of the first loop L1 or the second loop L2.
• a base material is arranged on the opposite adhesive surface of the seam tape at the end adhesive portion, but in this embodiment, no base material is arranged at the end adhesive portion 5.
• Figure 7 is an image of the adhesive lock thread portion 51 and its surrounding area taken with a scanning electron microscope (SEM) (MiniscopeTM3000, manufactured by Hitachi High-Technologies Corporation). The set magnification of the SEM image is 30x. As shown in Figure 7, in the end adhesive portion 5, the amount of first adhesive 91 distributed in the adhesive lock thread portion 51 along the lock thread S1 (base thread Sa) is greater than the amount of second adhesive 92 distributed in the other portion R. In this embodiment, the adhesive lock thread portion 51 is the area including the portion 51 where the lock thread S1 is located and its vicinity 52.
• SEM scanning electron microscope
• the amount of adhesive 91 may be, for example, the thickness of the adhesive 91 layered on the first fabric 2 and the second fabric 3.
• the thickness t1 of the adhesive 91 distributed in the adhesive lock thread portion 51 is thicker than the thickness t2 of the adhesive 92 distributed in the other portion R.
• first end 21 and the second end 31 are stitched together with sewing thread S4 to form a seam 4.
• first end 21 and the second end 31 are laid down to one side and then bonded to the back surface 3b of the main body 30 of the second fabric 3 to form an end bonding section 5, thereby obtaining an end fixing structure 1 for the two sewn together fabrics 2, 3.
• the heat-sealable sewing thread S1 offers the following advantages:
• the heat-sealable sewing thread S1 of this embodiment comprises a base thread Sa, a first heat-sealable thread Sb containing a heat-melting component and twisted with the base thread Sa using an S twist, and a second heat-sealable thread Sc containing a heat-sealable component and twisted with the base thread Sa using a Z twist around the outer periphery of the first heat-sealable thread Sb.
• the heat-sealable sewing thread S1 when used as a lock thread to overlock the ends 21, 31 of two pieces of fabric (first fabric 2, second fabric 3), and the ends 21, 31 are overlocked on one side or both sides, the first and second heat-sealable threads Sb, Sc are melted after overlocking, and the adhesive 91 distributed along the heat-sealable sewing thread S1 secures the ends 21, 31 of the first fabric 2 and the second fabric 3 to the main body 30 of the second fabric 3. Furthermore, even when the first and second heat-sealable threads Sb, Sc are melted, the base thread Sa remains in the overlocked areas, preventing fraying of the ends due to aging, which occurs when the fabric ends are secured only with adhesive.
• the adhesive 91 is distributed along the first and second heat-sealing threads Sb, Sc, which prevents excessive distribution of adhesive compared to when a hot melt or other tape material is applied to the entire edge of the fabric. This prevents the fabric from hardening and increasing in weight, while still providing an attractive fixed edge. Because the edges of the fabric are overlocked, they can be seamlessly connected in the direction of extension of the locking thread S1, more effectively fixing the edges 21, 31 of the first and second fabrics 2, 3 to the main body 30 of the second fabric 3.
• the weight ratio of the first heat-sealing thread Sb and the second heat-sealing thread Sc to the weight of the heat-sealing sewing thread S1 is 25% or more and 50% or less.
• the thickness of the base thread will become thinner, making the seam strength weaker, assuming the thickness of the sewing thread remains constant.
• This configuration allows the melting temperature of the first and second heat-sealing threads Sb and Sc to be appropriately set. If the melting temperature is below 100°C, the first and second heat-sealing threads Sb and Sc may melt due to the temperature of the sewing needle, which increases due to frictional heat between the sewing needle and the fabric during sewing. Furthermore, ironing or tumble drying of the finished product may cause the threads to melt, resulting in a loss of adhesive function. If the melting temperature exceeds 200°C, the color fastness generally decreases, the fabric is prone to discoloration, and the fabric itself may even melt.
• the number of twists of the first and second heat-sealed yarns Sb, Sc can be appropriately set. If the number of twists of the first and second heat-sealed yarns is less than 450 times/m, the heat-sealed yarns will be loosely wound and prone to unraveling; if it exceeds 550 times/m, the density of the heat-sealed yarns will be excessive, which will likely increase costs.
• This configuration allows the ratio of the diameter Z1 of the heat-sealable sewing thread S1 to the length Z of the major axis 61a of the thread hole 61 of the sewing needle 6 to be appropriately set. If the ratio of the diameter Z1 of the heat-sealable sewing thread S1 is less than 0.35, the thickness of the heat-sealable sewing thread S1 will be insufficient, making it difficult to achieve the required sewing strength. If the ratio of the thickness Z1 of the heat-sealable sewing thread S1 exceeds 0.9, the temperature of the sewing needle 6 will rise due to frictional heat generated between the thread hole 61 and the inserted heat-sealable sewing thread S1, which may cause the first and second heat-sealable threads Sb and Sc to melt.
• the rigidity is not excessive and the texture is less likely to be impaired. Furthermore, with this configuration, it is possible to bond not only synthetic fibers but also natural fibers, broadening the range of materials that can be bonded.
• the end fixing structure 1 comprises a first fabric 2 having a first end 21, a second fabric 3 having a second end 31, a locking thread S1 that overlocks the first end 21 and the second end 31, a sewn portion 4 where the first end 21 and the second end 31 are sewn together with a sewing thread S4, and an end adhesive portion 5 where the first end 21 and the second end 31 are folded down on one side or both sides and adhered to the main body portion 20 of the first fabric 2 and/or the main body portion 30 of the second fabric 3, and in the end adhesive portion 5, the amount of adhesive 91 distributed in the adhesive portion locking thread portion along the locking thread S1 is greater than the amount of adhesive 92 distributed in the other portion R.
• the first end 21 and the second end 31 can be fixed to the main body 30 by the adhesive 91 distributed in the adhesive lock thread portion 51.
• the amount of adhesive 92 distributed in the other portion R is reduced compared to the amount of adhesive 91 distributed in the adhesive lock thread portion 51, which prevents excessive distribution of adhesive compared to when a tape material such as hot melt is applied to the entire end adhesive portion 5. This prevents the fabric from hardening and increasing in weight, while allowing the fabric ends to be fixed in an attractive manner. Because the first end 21 and the second end 31 are overlocked, a continuous end adhesive portion 5 can be formed without interruption in the direction of extension of the lock thread S1, more effectively fixing the first end 21 and the second end 31 to the main body 20, 30.
• first end 21 and the second end 31 are oversewn together with the locking thread S1, which simplifies the process for securing the ends compared to when the first end 21 and the second end 31 are oversewn separately.
• Simply providing an adhesive locking thread portion 51 on the side of the first back locking thread S11 or the second back locking thread S12 that is tilted to one side and positioned facing the main body portions 20, 30 secures the first end 21 and the second end 31 to the main body portions 20, 30, while also reducing the amount of adhesive used compared to when an adhesive locking thread portion is also provided on the other side.
• the first end 21 and second end 31, which are oversewn with a locking thread S1 containing thermal adhesive threads Sb and Sc, can be secured to the main body portions 20 and 30.
• a tape material such as hot melt adhesive
• excessive distribution of adhesive can be prevented. This prevents the fabric from hardening and increasing in weight, while securing the fabric edges in an attractive manner.
• the first end 21 and the second end 31 are sewn together with a locking thread S1 by overlock stitching.
• the locking thread S1 comprises a first back locking thread S11 located on the back surface 2b of the first end 21 and a second back locking thread S12 located on the back surface 3b of the second end 31.
• At least the first back locking thread S11 or the second back locking thread S12, which is tilted to one side and positioned opposite the main body portions 20, 30, comprises heat-sealing threads Sb, Sc.
• This configuration allows the overlock pitch P1 to be appropriately set. If the pitch P1 is less than 0.5 mm, it is difficult to move the sewing needle using a sewing machine, etc., and if the pitch P1 exceeds 3.0 mm, the molten adhesive 91 distributed in the adhesive lock thread portion 51 along the lock thread S1 is likely to become discontinuous in some areas, making it difficult to prevent the first end portion 21 and the second end portion from peeling off the main body portions 20, 30.
• the sewing speed of the lock thread S1 can be adjusted by the rotation speed of the sewing machine motor (not shown), which is set to between 3000 rpm and 8000 rpm.
• This configuration allows the sewing speed to be set appropriately. If the sewing speed is less than 3,000 rpm, production efficiency will decrease. If the sewing speed exceeds 8,000 rpm, the temperature of the sewing needle 6 is likely to rise due to frictional heat between the sewing needle 6 and the fabric during sewing, and the temperature rise of the sewing needle 6 may cause the thermal fusion threads Sb and Sc to melt.
• the first back lock yarn S11 and the second back lock yarn S12 are described as including heat-sealed yarns Sb and Sc, but this is not limited to this.
• the second back lock yarn S12 which is arranged opposite the back surface 3b of the main body portion 30 of the second fabric 3 that is laid down to one side, may include heat-sealed yarns Sb and Sc
• the first back lock yarn S11 may be composed of a so-called regular yarn such as a spun yarn or filament yarn that does not include heat-sealed yarns Sb and Sc.
• a spun yarn is a spun yarn made by processing staple fibers.
• the first end 21 and the second end 31 are overcast using a single-needle, three-thread lockstitch machine, but this is not limited to this.
• the first end 21 and the second end 31 may also be overcast using a two-needle, four-thread lockstitch machine.
• one of the two needle threads may be used to replace the base stitch of the suture thread S4, as shown by the two-dot chain line in Figure 6.
• first end 21 and the second end 31 are overlocked, and then the first fabric 2 and the second fabric 3 are sewn together with a plain stitch, forming the sewn portion 4.
• this is not limited to this, and the sewn portion 4 (suture thread S4) may not be provided.
• first end 21 and the second end 31 are configured to be integrally overlocked, but this is not limited to this.
• first end 121 and the second end 131 may be overlocked with locking threads S5 and S6, respectively, and may also be folded down on both sides.
• the first fabric 102 may have a first end 121 overlocked with a first locking thread S5, a second end 131 of the second fabric 103 overlocked with a second locking thread S6, a sewn portion 104 where the first end 121 and the second end 131 are sewn together with a sewing thread S7, and end bonding portions 105, 105 where the folded first end 121 and second end 131 are bonded to the main body portion 120 of the first fabric 2 and the main body portion 130 of the second fabric 3, respectively.
• the locking thread has a first locking thread S5 that oversews the first end 121 and a second locking thread S6 that oversews the second end 131.
• the first locking thread S5 has a first back side thread S51 located on the back surface 102b of the first end 121 and a first front side thread S52 located on the front surface 102c.
• the second locking thread S6 has a second back side thread S61 located on the back surface 103b of the second end 131 and a second front side thread S62 located on the front surface 103c.
• the end adhesive portion 105 has both the first end 121 and the second end 131 folded down and adhesively bonded to the main body portions 120 and 130, respectively.
• the adhesive portion locking thread portion 51 is the portion where at least the first back side thread S51 and the second back side thread S61 that are arranged opposite the main body portions 120 and 130 are arranged.
• the first end 121 and the second end 131 can be bonded to the main body portions 120 and 130, respectively, using the adhesive 91 distributed in the adhesive lock thread portion 51.
• This embodiment shows an example of overlock stitching using a lockstitch machine, but other sewing methods such as lockstitching and zigzag stitching can also be applied. After sewing, problems such as fraying of the thread can be solved by subsequent thermocompression bonding.
• the motor rotation speed should preferably be between 3000 rpm and 5000 rpm.
• the stitched portion sewn with heat-sealable sewing thread S1 can be sewn by melting the first and second heat-sealable threads Sb, Sc after sewing, so that the needle holes formed by the stitching are closed by the first and second heat-sealable threads Sb, Sc, and the fabric can be sewn using the base thread Sa.
• by providing an end bonding portion that bonds the ends of the two pieces of fabric together with an adhesive or the like water can be prevented from entering between the two pieces of fabric.
• the heat-sealable sewing thread S1 of the present invention may be used to sew two or more layers of fabric together, such as in clothing, hats, bags, gloves, tents, tarps, sleeping bags, sheets, and umbrellas, or may be used to sew quilted areas that have two or more layers of fabric and filling, such as down and bedding.
• the heat-sealable sewing thread S1 according to the present invention is not limited to the configuration of the above-described embodiment, and various modifications are possible.
• the waterproof joint structure 1001 has an end bonding portion 1004 that bonds a first end portion 1021 of a first fabric 1002 to a second end portion 1031 of a second fabric 1003, and a stitching portion 1005 where the first end portion 1021 and the second end portion 1031 are sewn together.
• the stitching portion 1005 stitches the first end portion 1021 and the second end portion 1031 together by a plain stitch.
• plain stitching is a sewing method in which two or more pieces of fabric are sewn together from the back with the front sides facing each other.
• the seam 1005 is formed by sewing the first fabric 1002 and the second fabric 1003 together from the back with the front sides facing each other.
• the first fabric 1002 and the second fabric 1003 are waterproof.
• the first fabric 1002 and the second fabric 1003 are made of, for example, woven fabric and/or knitted fabric.
• the first fabric 1002 and the second fabric 1003 can be made of, for example, a fabric with a water pressure resistance of 2,000 mm or more.
• the pitch P1001 of each first loop L1001, L1002 may be set to between 0.5 mm and 3.0 mm, and in this embodiment is set to 1.0 mm or 2.0 mm.
• the pitch P1001 of the first loops L1001, L1002 corresponds to the pitch of the feed stitches of a lockstitch machine and is the longitudinal separation distance between adjacent first loops L1001, L1002.
• the pitch P1001 is 2.0 mm
• the number of stitches is 14 stitches/3 cm
• the pitch P1001 is 3.0 mm
• the number of stitches is 22 stitches/3 cm.
• the number of stitches is the number of perforations per 3 cm.
• the width W1001 of each first loop L1001, L1002 may be set to between 5 mm and 8 mm, for example, 6 mm.
• the width W1 of each first loop L1001, L1002 corresponds to the stitch width of the serger and is the distance from the edge 1002a of the first fabric 1002 to the end L1011, L1021 of each first loop L1001, L1002 on the side opposite the edge 1002a of the first fabric 1002.
• Needle threads S1003 are arranged on the end portions L1011, L1021 of each first front loop L1001 and each first back loop L1002, connecting adjacent first front loops L1001 and first back loops L1002, respectively, to form continuous stitches in the longitudinal direction.
• the needle threads S1003 include a right needle thread S1031 located on the edge portion 1002a side and a left needle thread S1032 located on the opposite side to the edge portion 1002a.
• the needle thread S1003 fixes the multiple first loops L1001, L1002 to the first fabric 1002 and prevents adjacent first loops L1001 from separating in the longitudinal direction.
• the multiple first loops L1001, L1002 are continuous in the longitudinal direction at the ends L1011, L1021 via the needle thread S1003.
• the first one-side thread S1011 and the first other-side thread S1012 intersect with each other at the edge 1002a.
• the multiple first front loops L1001 and first back loops L1002 are continuous in the longitudinal direction at the edge 1002a.
• the second end 1031 is located at the end of at least one widthwise side of the second fabric 1003.
• the second end 1031 is overlocked with a second locking thread S1002. Because the second end 1031 has the same configuration as the first end 1021, a detailed description will be omitted, and the configuration of the second end 1031 will be indicated in parentheses in Figure 11.
• the second end 1031 is overlocked with a second lock thread S1002.
• the multiple second loops L1003, L1004 that make up the overlock stitch include a second front loop L1003 and a second back loop L1004 that extend continuously along the edge 1003a of the second fabric 1003.
• the second lock thread S1002 includes a second one-side thread S1021 that makes up the second front loop L1003 and a second other-side thread S1022 that makes up the second back loop L1004.
• the second lock thread S1002 has a swing width W1001 and a pitch P1001 set for the second loops L1003, L1004.
• Figure 12 shows the sewing process in which the first fabric 1002 and the second fabric 1003 are sewn together with a plain stitch after the first end 1021 and the second end 1031 have been overlocked.
• Figure 12 simply shows the overlock stitches (first lock thread S1001 and second lock thread S1002) of the first end 1021 and the second end 1031.
• the first fabric 1002 and the second fabric 1003 are arranged so that the surface 1002b of the first fabric 1002 faces the surface 1003b of the second fabric 1003, and the edges 1002a, 1003a of the first fabric 1002 and the second fabric 1003 are aligned, and the sewing thread S1004 is sewn together to form the seam 1005.
• the surface 1002b of the first fabric 1002 may be the first opposing surface, and the surface 1003b of the second fabric 1003 may be the second opposing surface.
• the back surface 1002c of the first fabric 1002 may be the first opposing surface, and the back surface 1003c of the second fabric 1003 may be the second opposing surface.
• FIG 13 shows a cross section taken along line XIII-XIII during the sewing process in Figure 12.
• a sewing thread S1004 is arranged in the sewing portion 1005.
• the sewing thread S1004 includes a first sewing thread S1041 located on the back surface 1002c of the first fabric 1002 and a second sewing thread S1042 located on the back surface 1003c of the second fabric 1003.
• the first lock yarn S1001 is formed by spirally winding heat-sealing yarns Sb and Sc, which contain heat-sealing components, around a base yarn Sa, which does not contain heat-sealing components.
• the base yarn Sa is formed, for example, from a polyester two-ply yarn or a three-ply twisted filament yarn (e.g., a filament yarn of 75 dtex to 80 dtex, formed by a three-ply twist of 24 filament yarns).
• the heat-sealing yarns Sb and Sc may be any polyamide-based fusion yarn, for example, a filament yarn of 75 dtex to 80 dtex, formed by five filament yarns.
• a filament yarn is a yarn formed by twisting multiple long fibers together.
• the melting temperature of the heat-sealing thread Sb may be set to between 100°C and 200°C, for example, 120°C or 130°C. While the first locking thread S1001 has been described in Figure 14, the second locking thread S1002, needle thread S1003, and suture thread S1004 also have base thread Sa and heat-sealing thread Sb, just like the first locking thread S1001.
• the twist count of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to between 450 turns/m and 550 turns/m, and in this embodiment, the twist count is set to approximately 500 turns/m.
• the twist angle ⁇ of the lower heat-sealed yarn Sb may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• the twist angle ⁇ of the upper heat-sealed yarn may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• each twist angle ⁇ , ⁇ is the angle between the axis X1 of the base yarn Sa and the lower heat-sealed yarn Sb or the upper heat-sealed yarn Sc.
• FIG. 15 is an enlarged cross-sectional view showing the encircled area of the eye 1061 of the sewing needle 1006 used to sew the first fabric 1002 and the second fabric 1003 together.
• the eye 1061 of the sewing needle 1006 is roughly elliptical in shape, having a major axis 1061a and a minor axis 1061b.
• the width d1 of the sewing needle 1006 is preferably small in order to reduce the diameter d of the needle eye in the first fabric 1002 and the second fabric 1003. On the other hand, it is preferable that the eye 1061 be large relative to the width d1 of the sewing needle 1006.
• the heat-sealed yarns Sb, Sc of the first locking thread S1001 and the second locking thread S1002 of the first end 1021 and the second end 1031 are melted by heat and then cooled, bonding the first end 1021 and the second end 1031.
• the end bonding portion 1004 is distributed with adhesive 1091 remaining after the heat-sealed yarns Sb, Sc of the first locking thread S1001 and the second locking thread S1002 have melted. More specifically, as shown in FIG.
• the end bonded portion 1004 is a portion where the first end 1021 and the second end 1031 are bonded together by adhesive 1091 distributed in the bonded portion lock thread portion 1041 along the first and second lock threads S1001 and S1002.
• the end bonded portion 1004 is arranged between the edge portions 1002a, 1003a of the first fabric 1002 and the second fabric 1003 and the ends L1011, L1021, L1031, L1041 of the first loops L1001, L1002 and the second loops L1003, L1004.
• the width of the end bonded portion 1004 is approximately the same as the width W1001 of the first loops L1001, L1002 and the second loops L1003, L1004.
• a base material is arranged on the opposite adhesive side of the seam tape at the end bonded portion, but in this embodiment, no base material is arranged at the end bonded portion 1004.
• the width of the edge adhesive must be set larger than the loop width W1001 in order to prevent water from seeping in through the seams. This means that the area in which the base material is placed is wider, making it more likely to become stiffer. However, no base material remains at the edge adhesive 1004, and the width of the edge adhesive 1004 roughly matches the loop width W1001, making it easier to prevent this increase in stiffness.
• Figure 17 is an image of the adhesive lock thread portion 1051 and its surrounding area taken with a scanning electron microscope (SEM) (MiniscopeTM3000, manufactured by Hitachi High-Technologies Corporation). The set magnification of the SEM image is 30x.
• SEM scanning electron microscope
• the amount of adhesive 1091 distributed in the adhesive lock thread portion 1041 along the first lock thread S1001 and second lock thread S1002 (base thread Sa) is greater than the amount of adhesive 1092 distributed in the other portion R.
• the adhesive lock thread portion 1041 is the region including the portion 1041 where the first and second lock threads S1001, S1002 are arranged and its vicinity 1042.
• the amount of adhesive 1091, 1092 may be, for example, the thickness of adhesive 1091, 1092 layered on the first fabric 1002 and the second fabric 1003.
• the thickness t1 of adhesive 1091 distributed in the adhesive lock thread portion 1041 is thicker than the thickness t2 of adhesive 1092 distributed in the other portion R.
• the heat-sealed threads Sb and Sc of the suture thread S4 are also melted.
• the seam 1005 closes the needle hole 1051 formed during the base stitching with the heat-sealed threads Sb and Sc, and is sewn together with the base thread Sa.
• the adhesive lock thread portion 1041 and the suture thread portion 1052 are sewn using a sewing machine.
• the sewing speed of the adhesive lock thread portion 1041 and the suture thread portion 1052 can be adjusted by the rotation speed of the sewing machine motor.
• the rotation speed of the sewing machine motor may be set to between 3000 rpm and 8000 rpm, for example, 4000 rpm.
• a waterproof first fabric 1002 and a second fabric 1003 are prepared.
• the first end 1021 which is the end on one side of the width of the first fabric 1002, is oversewn with a first locking thread S1001 containing heat-sealing threads Sb and Sc.
• the second end 1031 which is the end on one side of the width of the second fabric 1003, is oversewn with a second locking thread S1002 containing heat-sealing threads Sb and Sc.
• the first end 1021 and the second end 1031 are overlapped with the front sides facing each other and stitched together with a suture thread S1004 containing thermal fusion threads Sb and Sc to form the seam 1005.
• a suture thread S1004 containing thermal fusion threads Sb and Sc to form the seam 1005.
• heat is applied to the first end 1021 and the second end 1031 to thermally fuse them together, and the first end 1021 and the second end 1031 are adhered to the back surface 1002c, 1003c of the first fabric 1002 or the second fabric 1003.
• the thermal fusion threads Sb and Sc of the suture thread S1004 of the seam 1005 melt to seal the needle hole 1051 with adhesive, thereby obtaining a waterproof joint structure 1001.
• Heating methods for applying heat to the first end 1021 and the second end 1031 include, for example, a heat press that applies heat, pressure, and cooling; ultrasonic heating that vibrates the first end 1021 and the second end 1031 with ultrasonic vibrations and melts and bonds the thermal fusion threads Sb and Sc with the frictional heat generated between the ends by the vibrations; and high-frequency heating that heats the material through potential movement at the molecular level using high-frequency energy (electromagnetic waves). These heating methods may be selected appropriately, or multiple heating methods may be combined, taking into consideration the fabric thickness, the number of fabric layers (the distance from the fabric surface to the fusion threads), and production efficiency.
• the waterproof joint structure 1001 according to this embodiment has the following advantages:
• the waterproof joint structure 1001 comprises a first fabric 1002 having a first end 1021, a second fabric 1003 having a second end 1031, an end bonding portion 1004 where the first end 1021 and the second end 1031 are bonded, and a stitched portion 1005 where the first end 1021 and the second end 1031 are sewn together with a suture thread and the needle hole 1051 of the suture thread S1004 is sealed with adhesive.
• the first fabric 1002 and the second fabric 1003 are sewn together with a plain stitch, so the end adhesive portion 1004 is not exposed on the surfaces 1002b and 1003b, resulting in an aesthetically pleasing appearance.
• the first end 1021 and the second end 1031 are oversewn with the first locking thread S1001 and the second locking thread S1002, respectively.
• the end adhesive portion 1004 is a portion where the first end 1021 and the second end 1031 are adhered by adhesive 1091 distributed in the adhesive portion locking thread portion 1041 along the first and second locking threads S1001, S1002.
• the amount of adhesive 1091 distributed in the adhesive portion locking thread portion 1041 is greater than the amount of adhesive 1092 distributed in the other portion R.
• the amount of adhesive 1092 distributed in the other portion R is reduced compared to the amount of adhesive 1091 distributed in the adhesive lock thread portion 1041, excessive distribution of adhesive can be prevented compared to when a tape material such as hot melt is applied to the entire end adhesive portion 1004. This prevents the fabric from hardening and becoming heavier, while still allowing the edges of the fabric to be fixed in place in an attractive manner.
• the first fabric 1002 and the second fabric 1003 each have a surface (first opposing surface) 2b of the first fabric 1002 and a surface (second opposing surface) 1003b of the second fabric 1003, which face each other.
• the first lock thread S1001 has a first one-side thread S1011 located on the surface 1002b of the first fabric 1002 and a first other-side thread S1012 located on the back surface (first opposite surface) 1002c.
• the second lock thread S1002 has a second one-side thread S1021 located on the surface 1003b of the second fabric 1003 and a second other-side thread S1022 located on the back surface (second opposite surface) 1003c.
• the adhesive lock thread portion 1041 is the portion where at least the first one-side thread S1011 and the second one-side thread S1021 are arranged.
• first end 1021 and the second end 1031 are bonded together by adhesive 1091 distributed in the adhesive lock thread portion 1041 along the first one-side thread S1011 and the second one-side thread S1021, which are arranged on the first opposing surface 1002b and the second opposing surface 1003b (the inner surface) where the surfaces 1002b, 1003b of the first end 1021 and the second end 1031 face each other, thereby preventing water from entering between the first fabric 1002 and the second fabric 1003.
• the waterproof joint structure is manufactured by overlocking the first end 1021 of the first fabric 1002 with a first locking thread S1001 containing thermal adhesive threads Sb and Sc, overlocking the second end 1031 of the second fabric 1003 with a second locking thread S1002 containing thermal adhesive threads Sb and Sc, sewing the first end 1021 and the second end 1031 together with a suture thread S1004 containing thermal adhesive threads Sb and Sc to form a seam 1005, melting the first locking thread S1001 and the second locking thread S1002 to thermally weld the first end 1021 and the second end 1031 to form an end bonded portion 1004, and melting the suture thread S1004 in the seam 1005 to close the needle hole 1051.
• the first fabric 1002 and the second fabric 1003 each have opposing surfaces (first opposing surface, second opposing surface) 1002b, 1003b.
• the first lock thread S1001 has a first one-side thread S1011 located on the surface 1002b of the first fabric 1002 and a first other-side thread S1012 located on the back surface 1002c.
• the second lock thread S1002 has a second one-side thread S10021 located on the surface 1003b of the second fabric 1003 and a second other-side thread S1022 located on the back surface 1003c. At least the first one-side thread S1011 and the second one-side thread S1021 include heat-sealing threads Sb, Sc.
• first end 1021 and the second end 1031 are bonded together by the heat-sealed yarns Sb and Sc contained in the first one-side thread S1011 and the second one-side thread S1021, which are arranged on the first opposing surface 1002b and second opposing surface 1003b where the first fabric 1002 and the second fabric 1003 face each other, thereby preventing water from entering between the first fabric 1002 and the second fabric 1003.
• the pitch P1001 of the overlock stitch formed by the first lock thread S1001 and the second lock thread S1002 is 0.5 mm or more and 3.0 mm or less.
• the overlock pitch P1001 can be appropriately set. If the pitch P1001 is less than 0.5 mm, it is difficult to move the sewing needle 1006 using a sewing machine or the like. If the pitch P1001 exceeds 3.0 mm, the molten adhesive 1091 distributed in the adhesive lock thread portion 1041 along the first lock thread S1001 and/or second lock thread S1002 is likely to become discontinuous in some areas, making it difficult to prevent water from entering between the first fabric 1002 and the second fabric 1003.
• the first locking thread S1001, the second locking thread S1002, and the suture thread S1004 are constructed by spirally winding heat-sealing threads Sb and Sc, which contain a heat-sealing component, around a base thread Sa, which does not contain a heat-sealing component.
• the melting temperature of the heat-sealing yarns Sb and Sc is between 100 and 200 degrees.
• the melting temperature of the thermal adhesive threads Sb and Sc can be appropriately set. If the melting temperature is below 100°C, the thermal adhesive threads Sb and Sc may melt due to the temperature of the sewing needle 1006, which rises due to frictional heat between the sewing needle 1006 and the fabric during sewing. Furthermore, ironing or tumble drying of the product may cause the threads to melt, resulting in a loss of adhesive function. If the melting temperature exceeds 200°C, the color fastness generally decreases, the fabric is prone to discoloration, and the fabric itself may even melt.
• the ratio of the diameter Z1 of the first locking thread S1001, the second locking thread S1002, and/or the suture thread S1004 to the length Z of the major axis 1061a of the thread eye 1061 of the sewing needle 1006 is 0.35 or more and 0.9 or less.
• the ratio of the diameter Z1 of the first locking thread S1001, the second locking thread S1002, and/or the suture thread S1004 to the length Z of the major axis 1061a of the thread hole 1061 of the sewing needle 1006 can be appropriately set. If the ratio of the diameter Z1 is less than 0.35, the thickness of the first locking thread S1001, the second locking thread S1002, and/or the suture thread S1004 will be insufficient, making it difficult to achieve the required sewing strength. If the ratio of the diameter Z1 to the major axis 1061a exceeds 0.9, the temperature of the sewing needle 1006 will rise due to frictional heat generated between the thread hole 1061 and the thread being inserted, which may cause the heat-sealing threads Sb and Sc to melt.
• the thickness and diameter Z1 of the sewing needle 1006 are constant, when the ratio of diameter Z1 is less than 0.35, the thread hole 1061 becomes relatively large, reducing the strength of the sewing needle 1006. If the diameter Z1 is constant while maintaining the strength of the sewing needle 1006, when the ratio of diameter Z1 exceeds 0.9, the thickness of the sewing needle 1006 becomes thicker, the pinhole 1051 formed in the first fabric 1002 or the second fabric 1003 becomes larger, and depending on the amount of adhesive 1093, it becomes difficult to seal the pinhole 1051, making it difficult to prevent water from entering through the pinhole 1051.
• the first end 1121 and the second end 1131 are sewn together with a sewing thread S1104 including thermal adhesive threads Sb and Sc, which prevents water from entering through the pinhole in the stitched portion 1105. Furthermore, by placing hot melt H2 on the back surface 1103c of the second end 1131, the first end 1121 and the second end 1131 can be adhered to the back surface 1103c of the second fabric 1103 when they are folded to one side.
• the hot melts H1 and H2 are made of a thermoplastic resin or the like.
• the first end 1221 and the second end 1231 may be adhered with an adhesive member H1, and the first end 1221 and the second end 1231 may be oversewn with a first locking thread S1201 in a state where the two end portions 1221, 1231 are overlapped with each other.
• the first end 1221 and the second end 1231 do not have to be oversewn individually, and the first end 1221 and the second end 1231 may be oversewn together with the first locking thread S1201.
• the first lock thread S1201 can be bonded to the back surface 1203c of the second fabric 1203 when the first end 1221 and the second end 1231 are folded to one side by forming the first one side thread S1211 of the first lock thread S1201 located at least on the back surface 1203c side of the second end 1231 with a thread containing heat-sealing threads Sb and Sc.
• the first other side thread S1212 of the first lock thread S1201 may be formed with a thread that does not contain heat-sealing threads Sb and Sc.
• the first end 1021 and the second end 1031 are overcast using a single-needle, three-thread lockstitch machine, but this is not limited to this.
• the first end 1021 and the second end 1031 may also be overcast using a two-needle, four-thread lockstitch machine.
• one of the two needle threads may be used in place of the base stitch of the suture thread S1004, as shown by the two-dot chain line in Figure 20.
• the end adhesive portion 1004 is configured as a portion where the first end 1021 and the second end 1031 are adhered by adhesive 1009 distributed in the adhered end lock thread portion 1041 along the first lock thread S1001 and the second lock thread S1002.
• the end adhesive portion 1304 may be configured as an ultrasonically fused portion where the first fabric 1302 and the second fabric 1003 are melted and joined to the first end 1321 and the second end 1331 without the use of adhesive. With this configuration, the ultrasonically fused portion 1304 can adhere the first end 1321 and the second end 1331, thereby preventing water from entering between the first fabric 1302 and the second fabric 1003.
• the waterproof joint structure 1301 is manufactured by preparing a first fabric 1302 having a first end 1321 and a second fabric 1003 having a second end 1331, ultrasonically joining the first end 1321 and the second end 1331 while they are overlapped to form an end joint 1304, sewing the first end 1321 and the second end 1331 together with a suture thread S4 containing heat-sealing thread Sb to form a seam 1305, and melting the suture thread S1004 of the seam 1305 to close the needle hole 1351.
• the first end 1521 and the second end 1531 may be bonded with an adhesive material such as hot melt H5 placed between the first end 1521 and the second end 1531.
• the suture thread S1504 may be configured to include heat-sealing threads Sb and Sc
• the first locking thread S1501 and the second locking thread S1502 may be configured, for example, with base thread Sa without including heat-sealing threads Sb and Sc.
• the waterproof joining structure 1001 of the present invention may be applied to sewing together two or more pieces of fabric that require waterproofing, such as clothing, hats, bags, gloves, tents, tarps, sleeping bags, sheets, and umbrellas.
• the waterproof joint structure 1001 of the present invention was applied to clothing, and waterproofing tests were conducted, resulting in no water leakage in anticipated wearing situations (for example, the garment can be worn without getting wet while playing golf, running, watching sports, or working outdoors in the rain).
• the waterproofing test was carried out by having a mannequin or subject wear clothing equipped with the waterproof joint structure 1001 of the present invention, adjusting the artificial rainfall test device to a rainfall rate of 30 mm/h, and allowing rain to fall for 30 minutes, and then visually inspecting the mannequin or subject for the presence or absence of water penetration into the interior of the mannequin or subject.
• the waterproof joint structure 1001 of the present invention allows for flexible fabric selection and simple sewing, making it possible to target a niche market where conventional windbreakers are unable to withstand rain and outdoor rainwear such as hard shells are stiff and expensive due to their tape-type joint structure.
• FIG. 24 shows a plan view of two pieces of fabric (a first fabric 2002 and a second fabric 2003) equipped with an end fixing structure 2001 using heat-sealable sewing thread according to one embodiment of the present invention. As shown in Fig.
• plain stitching is a sewing method in which two or more pieces of fabric are sewn together from the wrong side with the front sides facing each other.
• the seam 2004 is formed by sewing the first fabric 2002 and the second fabric 2003 together from the wrong side with the front sides facing each other.
• the first fabric 2002 and the second fabric 2003 are made of, for example, woven fabric and/or knitted fabric.
• the first fabric 2002 and the second fabric 2003 are made of, for example, 100% synthetic polyester fabric. Note that this heat-sealing thread can be used to bond fabrics made of natural fibers as well as synthetic fibers.
• the first end 2021 is located on one side in the width direction of the first fabric 2002.
• the second end 2031 is located on one side in the width direction of the second fabric 2003.
• the first end 2021 and the second end 2031 are overlocked with a locking thread S2001.
• the first end 2021 and the second end 2031 are sewn together integrally with a locking thread S2001.
• the lock thread S2001 comprises a first back lock thread S2011 located on the back surface 2002b of the first fabric 2002 and a second back lock thread S2012 located on the back surface 2003b of the second fabric.
• the first back lock thread S2011 forms a plurality of first loops L2001 that are continuous in the longitudinal direction on the back surface 2002b of the first fabric 2002.
• the second back lock thread S2012 forms a plurality of second loops L2002 that are continuous in the longitudinal direction on the back surface 2003b of the second fabric 2003.
• the pitch P2001 of each of the first and second loops L2001, L2002 may be set to between 0.5 mm and 3.0 mm, and in this embodiment is set to 1.0 mm or 2.0 mm.
• the pitch P2001 of the first and second loops L2001, L2002 corresponds to the feed stitch pitch of a lockstitch machine and is the longitudinal separation distance between adjacent first and second loops L2001, L2002.
• the pitch P2001 is 2.0 mm
• the number of stitches is 14 stitches/3 cm
• the pitch P2001 is 3.0 mm
• the number of stitches is 22 stitches/3 cm.
• the number of stitches is the number of perforations per 3 cm.
• the width W1 of each of the first and second loops L2001, L2002 may be set to between 5 mm and 8 mm, for example, 6 mm.
• the width W2001 of each of the first and second loops L2001, L2002 corresponds to the swing width of the serger and is the distance from the edge portions 2002a, 2003a of the first fabric 2002 and the second fabric 2003 to the ends L2011, L2021 on the opposite edge portions 2002a, 2003a of each of the first and second loops L2001, L2002.
• Needle threads S2003 are arranged on the end portions L2011, L2021 of each first loop L2001 and each second loop L2002, connecting adjacent first loops L2001 and adjacent second loops L2002, respectively, to form continuous stitches in the longitudinal direction.
• the needle threads S2003 include a right needle thread S2031 located on the edge portion 2002a, 2003a side and a left needle thread S2032 located on the anti-edge portion 2002a, 2003a side.
• the needle thread S2003 fixes the multiple first and second loops L2001, L2002 to the first and second fabrics 2002, 2003, and prevents adjacent first loops L2001 from separating in the longitudinal direction.
• the multiple first and second loops L2001, L2002 are continuous in the longitudinal direction at the ends L2011, L2021 via the needle thread S2003.
• the first back lock thread S2011 and the second back lock thread S2012 intersect with each other at the edge 2002a.
• the multiple first loops L2001 and second loops L2002 are continuous in the longitudinal direction at the edge 2002a.
• Figure 26 shows the sewing process in which the first fabric 2002 and the second fabric 2003 are sewn together with a plain stitch after the first end 2021 and the second end 2031 have been overlocked.
• Figure 26 shows the first end 2021 and the second end as being offset, and the overlock stitches (lock thread S2001) of the first end 2021 and the second end 2031 are simply shown.
• the first fabric 2002 and the second fabric 2003 are sewn together with the sewing thread S2004, with the surface 2002c of the first fabric 2002 and the surface 2003c of the second fabric 2003 facing each other and the edges 2002a, 2003a of the first fabric 2002 and the second fabric 2003 aligned. This forms the sewn portion 2004.
• Figure 27 is an enlarged schematic diagram showing the locking thread S2001 alone.
• the locking thread S2001 is composed of threads containing heat-sealing threads Sb and Sc.
• the lock yarn S2001 is formed by spirally winding heat-sealing yarns Sb and Sc, which contain heat-sealing components, around a base yarn Sa, which does not contain heat-sealing components.
• the base yarn Sa is formed, for example, from a polyester two-ply yarn or a triple-ply twisted filament yarn (e.g., a filament yarn of 75 dtex to 80 dtex, formed by triple-twisting a filament yarn composed of 24 single yarns).
• the heat-sealing yarns Sb and Sc may be any polyamide-based fusion yarn, for example, a filament yarn of 75 dtex to 80 dtex, formed from five single yarns.
• a filament yarn is a yarn formed by twisting multiple long fibers together.
• dtex (decitex) is an SI unit used to express the thickness of a filament yarn (long fiber).
• 1 dtex is the thickness of a yarn that is 10,000 m long and weighs 1 g.
• the ratio of the heat-sealing yarns Sb and Sc to the weight of the lock yarn S2001 should be set to 25% or more and less than 50%, for example, 39%.
• the fusion yarns Sb, Sc include a lower heat fusion yarn Sb that covers the base yarn Sa, and an upper heat fusion yarn Sc that covers the lower heat fusion yarn Sb. It is preferable that the twist directions of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc relative to the base yarn Sa be opposite from the standpoint of sewability.
• the twist direction of the lower heat fusion yarn Sb is an S twist (right twist) relative to the base yarn Sa.
• the twist direction of the upper heat fusion yarn Sc is a Z twist (left twist) relative to the base yarn Sa.
• the twist count of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to between 450 turns/m and 550 turns/m, and in this embodiment, the twist count is set to approximately 500 turns/m.
• the twist angle ⁇ of the lower heat-sealed yarn Sb may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• the twist angle ⁇ of the upper heat-sealed yarn may be set to between 10 degrees and 30 degrees, inclusive, and is set to approximately 20 degrees in this embodiment.
• each twist angle ⁇ , ⁇ is the angle between the axis X1 of the base yarn Sa and the lower heat-sealed yarn Sb or the upper heat-sealed yarn Sc.
• the diameter Z1 of the first lock thread S2001 may be set to between 0.35 and 0.9 times the length Z of the major axis 2061a of the thread eye 2061 of the sewing needle 2006, and is set to, for example, 0.5 times.
• the end bonded portion 2005 is a portion where the first end portion 2021 and the second end portion 2031 are bonded to the main body portion 2030 of the second fabric 2003 by adhesive 2091 distributed in the bonded portion lock thread portion 2051 along the lock thread S2001.
• the amount of adhesive 2091 may be, for example, the thickness of adhesive 2091 layered on the first fabric 2002 and the second fabric 2003.
• the thickness t1 of adhesive 2091 distributed in the adhesive lock thread portion 2051 is thicker than the thickness t2 of adhesive 2092 distributed in the other portion R.
• the adhesive lock thread portion 2051 is sewn using a sewing machine.
• the sewing speed of the adhesive lock thread portion 2051 can be adjusted by the rotation speed of the sewing machine motor.
• the rotation speed of the sewing machine motor may be set to between 5000 rpm and 8000 rpm, and is set to, for example, 4000 rpm.
• the first end 2021 and the second end 2031 have end adhesive portions 2005 bonded to the main body 2030, which prevents the seam allowance 2041 from rising, making it less likely for a depression to occur in the seam allowance 2041 on the surface side of the fabric, making it easier to maintain a flat state and less likely to be unsightly.
• the pitch P2001 of the overlock stitch formed by the lock thread S2001 is 0.5 mm or more and 3.0 mm or less.
• the lock thread S2001 is constructed by spirally winding heat-sealing threads Sb and Sc, which contain heat-sealing components, around a base thread Sa, which does not contain heat-sealing components.
• the ratio of heat-sealing threads Sb and Sc to the weight of lock thread S2001 is between 25% and 50%.
• the thickness of the base yarn Sa will become thinner, and the seam strength will likely weaken, assuming the thickness of the locking yarn S2001 is constant.
• the melting temperature of the heat-sealing yarns Sb and Sc is between 100 and 200 degrees.
• the ratio of the diameter Z1 of the lock thread S2001 to the length Z of the major axis 2061a of the thread hole 2061 of the sewing needle 2006 through which the lock thread S2001 is inserted is 0.35 to 0.9.
• the ratio of the diameter Z1 of the lock thread S2001 to the length Z of the major axis 2061a of the thread hole 2061 of the sewing needle 2006 can be appropriately set. If the ratio of the diameter Z1 of the lock thread S2001 is less than 0.35, the thickness of the lock thread S2001 will be insufficient, making it difficult to achieve the required sewing strength. If the ratio of the diameter Z1 of the lock thread S2001 exceeds 0.9, the temperature of the sewing needle 2006 will rise due to frictional heat generated between the thread hole 2061 and the inserted lock thread S2001, which may cause the first and second thermal fusion threads Sb and Sc to melt.
• the sewing speed of the lock thread S2001 can be adjusted by the rotation speed of the sewing machine motor (not shown), which is set to between 3000 rpm and 8000 rpm.
• This configuration allows the sewing speed to be set appropriately. If the sewing speed is less than 3000 rpm, production efficiency will decrease. If the sewing speed exceeds 8000 rpm, the temperature of the sewing needle 2006 is likely to rise due to frictional heat between the sewing needle 2006 and the fabric during sewing, and the temperature increase of the sewing needle 2006 may cause the thermal fusion threads Sb and Sc to melt.
• the first end 2021 and the second end 2031 are overcast using a single-needle, three-thread lockstitch machine, but this is not limited to this.
• the first end 2021 and the second end 2031 may also be overcast using a two-needle, four-thread lockstitch machine.
• one of the two needle threads may be used in place of the base stitch of the suture thread S2004, as shown by the two-dot chain line in Figure 29.
• first end 2021 and the second end 2031 are overlocked, and then the first fabric 2002 and the second fabric 2003 are sewn together with a plain stitch, forming the sewn portion 2004.
• this is not limiting, and the sewn portion 2004 (suture thread S2004) may not be provided.
• first end 2021 and the second end 2031 are configured to be integrally overlocked, but this is not limited to this.
• the first end 2121 and the second end 2131 may be overlocked with locking threads S2005 and S2006, respectively, and may also be folded down on both sides.
• the first lock thread S5 has a first back side thread S2051 located on the back surface 2102b side of the first end 2121, and a first front side thread S2052 located on the front surface 2102c side.
• the second lock thread S2006 has a second back side thread S2061 located on the back surface 2103b side of the second end 2131, and a second front side thread S2062 located on the front surface 2103c side.
• the amount of adhesive 2091 distributed in the adhesive lock thread portion 2051 along the first lock thread S2005 and the second lock thread S2006 is greater than the amount of adhesive 2092 distributed in the other portion R.
• the adhesive lock thread portion 2051 may be at least the portion where the first back side thread S2051 and the second back side thread S2061, which are arranged opposite the main body portions 2120, 2130, are arranged.
• the lock thread has a first lock thread S2005 that oversews the first end 2121 and a second lock thread S2006 that oversews the second end 2131.
• the first lock thread S2005 has a first back side thread S2051 located on the back surface 2102b side of the first end 2121 and a first front side thread S2052 located on the front surface 2102c side.
• the second lock thread S2006 is located on the back surface 2103b side of the second end 2131.
• the end bonded portion 2105 has a first end 2121 and a second end 2131 that are folded down and bonded to the main body portions 2120 and 2130, respectively, and the bonded portion lock thread portion 2051 is a portion where at least the first back side thread S2051 and the second back side thread S2061 that are arranged opposite the main body portions 2120 and 2130 are arranged.
• the first end 2121 and the second end 2131 can be adhered to the main body portions 2120 and 2130, respectively, by the adhesive 2091 distributed in the adhesive lock thread portion 2051.
• the lock thread has a first lock thread S2005 for overlocking the first end 2121 and a second lock thread S2006 for overlocking the second end 2131.
• the first lock thread S2005 has a first back side thread S2051 located on the back surface 2102b side of the first end 2121 and a first front side thread S2052 located on the front surface 2102c side.
• the second lock thread S2006 has a first back side thread S2051 located on the back surface 2103b side of the second end 2131.
• the end bonding portion 2105 has a second back side thread S2061 located on the side of the first end 2121 and a second front side thread S2062 located on the side of the front surface 2103c, and the first end 2121 and the second end 2131 are folded down and bonded to the main body portions 2120 and 2130, respectively, and at least the first back side thread S2051 and the second back side thread S2061, which are arranged opposite the main body portions 2120 and 2130, have heat-sealed threads Sb and Sc.
• the first end 2121 and the second end 2131 can be bonded to the main body portions 2120, 2130 by the heat-sealing threads Sb, Sc contained in the first back side thread S20051 and the second back side thread S2061, which are arranged opposite each other on the main body portions 2120, 2130, of the first locking thread S2005 and the second locking thread S2006 of the folded-down first end portion 2121 and the second end portion 2131.
• the increase in adhesive can be suppressed.
• the end fixing structure 2001 of the present invention may also be applied to sewing together two or more pieces of fabric used in clothing, hats, bags, gloves, tents, tarps, sleeping bags, sheets, umbrellas, etc.
• the end fixing structure 2001 of the present invention can replace the seam allowance of clothing where overlock is used. Specifically, when used on parts that come into close contact with the wearer, such as the side seams, inner crotch seams, and hems of trousers, or the armholes and shoulder lines of jackets, it helps to reduce chafing and eliminate irritation.
• end fixing structure 2001 according to the present invention is not limited to the configuration of the above-described embodiment, and various modifications are possible.
• the one direction is an S twist, Aspect 2.
• the heat-bondable sewing thread according to aspect 1, wherein the other direction is a Z-twist.
• Aspect 3 The heat-fusible sewing thread according to aspect 1, wherein a ratio of the first heat-fusible yarn and the second heat-fusible yarn to a weight of the sewing thread is 25% or more and 50% or less.
• Aspect 4 The heat-fusible sewing thread according to any one of Aspects 1 to 3, wherein the melting temperatures of the first and second heat-fusible threads are 100°C or higher and 200°C or lower.
• Aspect 6 The heat-bondable sewing thread according to any one of Aspects 1 to 5, wherein the ratio of the diameter of the sewing thread to the length of the major axis of the thread eye of a sewing needle through which the sewing thread is inserted is 0.35 to 0.9 times.
• Aspect 7 The heat-fusible sewing thread according to any one of Aspects 1 to 6, wherein the first and second heat-fusible yarns are polyamide-based heat-fusible yarns.
• a method for manufacturing a waterproof joint structure using the heat-sealing sewing thread according to aspect 1 a first end portion of a waterproof first fabric is overlocked with a first locking thread including the heat-sealable sewing thread; a second end portion of the waterproof second fabric is overlocked with a second locking thread including the heat-sealable sewing thread; With the first end portion and the second end portion overlapped, the first fabric and the second fabric are sewn together with a sewing thread including the heat-fusible sewing thread to form a sewn portion; heat welding the first end and the second end to form an end bond; The suture thread of the suture portion is melted to close the needle hole.
• a method for manufacturing a waterproof joint structure a method for manufacturing a waterproof joint structure.
• the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other, the first lock yarn has a first one-side yarn located on the first opposing surface and a first other-side yarn located on a first opposite surface opposite to the first opposing surface, the second lock yarn has a second one-side yarn located on the second opposing surface and a second other-side yarn located on a second opposite surface opposite to the second opposing surface,
• the first one side thread and the second one side thread include the heat-fusible sewing thread.
• a method for manufacturing a waterproof joint structure providing a first fabric having a first end and a second fabric having a second end; ultrasonically bonding the first end and the second end in an overlapping state to form an end bond; forming a sewn portion by sewing the first end portion and the second end portion together with a suture thread including the heat-fusible sewing thread; The suture thread of the suture portion is melted to close the needle hole.
• a waterproof joint structure manufactured by the manufacturing method according to aspect 8, a first substrate having a first end; a second substrate having a second end; an end bonding portion at which the first end and the second end are bonded; a sewn portion in which the first end and the second end are sewn together with a suture thread and a needle hole of the suture thread is sealed with an adhesive.
• Aspect 13 The waterproof joint structure according to aspect 12, wherein the seam is formed by a plain stitch.
• the first end and the second end are overlocked with a first locking thread and a second locking thread, respectively;
• the end bonded portion is a portion where the first end and the second end are bonded by an adhesive distributed in a bonded portion lock yarn portion along the first and second lock yarns, In the end bonded portion, the amount of adhesive distributed in the bonded portion lock yarn portion is greater than the amount of adhesive distributed in other portions.
• the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other, the first lock yarn has a first one-side yarn located on the first opposing surface and a first other-side yarn located on a first opposite surface opposite to the first opposing surface, the second lock yarn has a second one-side yarn located on the second opposing surface and a second other-side yarn located on a second opposite surface opposite to the second opposing surface,
• the first end and the second end are sewn together by overlock stitching with the locking thread
• the lock yarn has a first back lock yarn located on the back side of the first end portion and a second back lock yarn located on the back side of the second end portion
• the locking yarn includes a first locking yarn for overlocking the first end and a second locking yarn for overlocking the second end
• the first lock yarn has a first back side yarn located on the back side of the first end portion and a first front side yarn located on the front side thereof
• the second lock yarn has a second back side yarn located on the back side of the second end portion and a second front side yarn located on the front side thereof
• the end bonding portion has the first end and the second end both laid down and bonded to the main body portion
• the locking yarn includes a first locking yarn for overlocking the first end and a second locking yarn for overlocking the second end
• the first lock yarn has a first back side yarn located on the back side of the first end portion and a first front side yarn located on the front side
• the second locking yarn has a second back side yarn located on the back side of the second end portion and a second front side yarn located on the front side thereof
• the end bonding portion has the first end and the second end both laid down and bonded to the main body portion
• Aspect 22 The end fixing structure according to aspect 21, wherein the adhesive portion lock yarn portion is at least a portion where the first back side yarn and the second back side yarn arranged opposite to the main body portion are arranged.

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