Thermally fusible sewing thread, waterproof joining structure using thermally fusible sewing thread, end fixing structure using thermally fusible sewing thread, and method for manufacturing same

Abstract

A thermally fusible sewing thread S1 includes: a base thread Sa; a first thermally fusible thread Sb that contains a thermally meltable component and is twisted in one direction that is either a S-twist direction or Z-twist direction with respect to the base thread Sa; and a second thermally fusible thread Sc that contains a thermally meltable component and is twisted in the other direction on the outer peripheral side of the first thermally fusible thread Sa with respect to the base thread Sa.

Description

Heat-sealable sewing thread, waterproof joint structure using heat-sealable sewing thread, end fixing structure using heat-sealable sewing thread, and manufacturing method thereof

[0001] The present invention relates to a heat-sealable sewing thread, a waterproof joint structure using the heat-sealable sewing thread, an end fixing structure using the heat-sealable sewing thread, and methods for manufacturing the same.

[0002] In general, for sewing and / or bonding fabrics, it is known to use a heat-fusible thread that is composed only of a fusible component and melts when heat is applied after sewing.

[0003] Patent Document 1 discloses a sewing thread having heat-fusible properties (heat-fusible sewing thread) in which a base thread not containing a heat-fusible component and a heat-fusible thread are paralleled or twisted together.

[0004] Japanese Patent Application Publication No. 7-216727

[0005] When fabrics are bonded together using only the heat-sealing thread, no sewing thread remains after the heat-sealing thread is melted, and the seam strength is likely to decrease compared to when sewing with a base thread. With the heat-sealing sewing thread of Patent Document 1, for example, when sewing with a sewing machine or the like, the base thread and the heat-sealing thread are likely to separate when the heat-sealing sewing thread passes through the eye of a sewing needle, making stable sewing difficult, and there is room for improvement.

[0006] An object of the present invention is to provide a heat-bondable sewing thread that provides seam strength and allows stable sewing.

[0007] One aspect of the present invention provides a heat-fusible sewing thread comprising: a base yarn; a first heat-fusible thread containing a heat-fusible component and twisted with respect to the base yarn in either an S-twist or a Z-twist; and a second heat-fusible thread containing a heat-fusible component and twisted around the outer periphery of the first heat-fusible thread in a direction different from the one direction with respect to the base yarn.

[0008] According to the present invention, since the twist directions and untwist directions of the first and second heat-sealing yarns are opposite to each other, the yarns are less likely to fray or become uneven compared to when the twist directions are the same. As a result, even when sewing with a sewing machine or the like, the base yarn, the first heat-sealing yarn, and the second heat-sealing yarn are less likely to separate, and the base yarn remaining in the sewn area provides seam strength and allows for stable sewing.

[0009] According to the present invention, it is possible to provide a heat-bondable sewing thread that provides seam strength and allows stable sewing.

[0010] 12. An explanatory diagram for explaining the configuration of a heat-fusible sewing thread according to the present invention. A schematic diagram showing a sewing needle and a thread eye. A plan view showing an end fixing structure when a heat-fusible sewing thread is applied to a locking thread for overlocking the ends of two pieces of fabric. An explanatory diagram showing the state in which a first fabric and a second fabric have been overlocked. A plan view for explaining the process of sewing two pieces of fabric equipped with an end fixing structure. A cross-sectional view schematically showing a cross section taken along line VI-VI in FIG. 3. An image of the bonded portion of the locking thread and its surroundings taken with a scanning electron microscope. A cross-sectional view schematically showing a cross section taken along line VIII-VIII in FIG. 7. A cross-sectional view showing a modified example of the end sewn portion. A plan view showing a waterproof joining structure using a heat-fusible sewing thread according to the present invention. An explanatory diagram showing the state in which the first fabric has been overlocked. A plan view for explaining the sewing process of a waterproof joining structure using a heat-fusible sewing thread according to the present invention. A cross-sectional view taken along line XIII-XIII in FIG. 12. An explanatory diagram for explaining the configuration of a first locking thread. 1. A schematic diagram showing a sewing needle and a thread eye. 2. A cross-sectional view showing a cross-section taken along line XVI-XVI in FIG. 10. 3. An image of the bonded lock thread portion and its surroundings taken with a scanning electron microscope. 4. A cross-sectional view showing a cross-section taken along line XVIII-XVIII in FIG. 8. 5. A cross-sectional view of the end sewn portion in a first modified example. 6. A cross-sectional view of the end sewn portion in a second modified example. 7. A cross-sectional view of the end sewn portion in a third modified example. 8. A plan view of a sewn portion in a fourth modified example. 9. A cross-sectional view of a sewn portion in a fifth modified example. 10. A plan view showing two pieces of fabric sewn together with an end fixing structure using a heat-fusible sewing thread according to the present invention. 11. An explanatory view showing the state in which the first and second fabrics have been overlocked. 12. A plan view illustrating the process of sewing two pieces of fabric with an end fixing structure using a heat-fusible sewing thread according to the present invention. 13. An explanatory view illustrating the configuration of the lock thread. 14. A cross-sectional view showing a sewing needle and a thread eye. A cross-sectional view schematically showing a cross section taken along line XXIX-XXIX in Figure 24. An image of the adhesive lock thread portion and its surroundings taken by a scanning electron microscope. A cross-sectional view schematically showing a cross section taken along line XXXI-XXXI in Figure 30. (a) A partially enlarged photograph showing the periphery of the seam of a conventional structure not provided with an end fixing portion, (b) A partially enlarged photograph showing the periphery of the seam of an end fixing structure according to the present invention provided with an end fixing portion. Cross-sectional views showing modified examples of the end sewn portion.

[0011] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0012] [First embodiment] Fig. 1 is an enlarged schematic view showing a single heat-sealable sewing thread S1 according to one embodiment of the present invention. As shown in Fig. 1, in this embodiment, the sewing thread S1 is made of a thread including first and second heat-sealable yarns Sb and Sc.

[0013] The heat-fusible sewing thread S1 is formed by spirally winding first and second heat-fusible yarns Sb, Sc, each containing a heat-fusible component, around a base yarn Sa containing no heat-fusible component. In this embodiment, the base yarn Sa is formed, for example, of 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 three-ply twisting a filament yarn consisting of 24 single yarns). The first and second heat-fusible yarns Sb, Sc may be polyamide-based fusible yarns, for example, a filament yarn having a thickness of 75 dtex to 80 dtex, formed by 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), with 1 dtex being the thickness of a thread that is 10,000 m long and weighs 1 g. The proportion of the first and second heat-fusible threads Sb, Sc to the weight of the heat-fusible sewing thread S1 may be set to 25% or more and less than 50%, and is set to, for example, 39%.

[0014] The melting temperature of the first and second heat-fusible yarns Sb, Sc may be set to 100 degrees or more and 200 degrees or less, for example, 120 degrees or 130 degrees.

[0015] As shown in FIG. 1 , the first and second heat fusion yarns Sb, Sc include a lower heat fusion yarn Sb as a first heat fusion yarn that covers a base yarn Sa, and an upper heat fusion yarn Sc as a second heat fusion yarn that covers the lower heat fusion yarn Sb. The twist directions of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc relative to the base yarn Sa are preferably opposite from the viewpoint of sewability. In this embodiment, 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 numbers of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to 450 turns / m or more and 550 turns / m or less, and in this embodiment, the twist number is set to approximately 500 turns / m. The twist angle α of the lower heat-fusion yarn Sb may be set to between 10 degrees and 30 degrees, and in this embodiment, it is set to about 20 degrees. The twist angle β of the upper heat-fusion yarn Sc may be set to between 10 degrees and 30 degrees, and in this embodiment, it is set to about 20 degrees. In this embodiment, each of the twist angles α and β is the angle between the axis X1 of the base yarn Sa and the lower heat-fusion yarn Sb or the upper heat-fusion yarn Sc.

[0016] FIG. 2 is an enlarged cross-sectional view schematically illustrating the area around the eye 61 of the sewing needle 6 through which the heat-sealable sewing thread S1 is inserted. As shown in FIG. 3, 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 hole created when sewing two pieces of fabric together. On the other hand, the eye 61 is preferably large relative to the width d1 of the sewing needle 6. For example, a sewing machine needle size 14 manufactured by Organ Needle Co., Ltd. may be used, in which the width d1 of the sewing needle 6 is 0.8 mm, the length of the major axis 61a of the eye 61 is set to approximately 0.8 mm, and the length of the minor axis 61b is set to approximately 0.3 mm. In this embodiment, 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 in the longitudinal direction.

[0017] As shown in FIG. 2, the diameter Z1 of the heat-fusible sewing thread S1 indicated by the two-dot chain line may be set to 0.35 to 0.9 times the length Z of the major axis 61a of the thread eye 61 of the sewing needle 6, for example, 0.5 times.

[0018] FIG. 3 shows an end fixing structure 1 in which a heat-fusible sewing thread S1 according to one embodiment of the present invention is used as a lock thread for fixing the ends of two pieces of fabric 2, 3.

[0019] 3, the end fixing structure 1 according to the present invention 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, and an end bonding portion 5 where the first end 21 and the second end 31 are turned down and bonded to the main body portion 30 of the second fabric 3. In this embodiment, the first fabric 2 and the second fabric 3 are sewn together at the sewn portion 4 by a plain stitch.

[0020] The "plain seam" 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, as described in JIS L0122. In other words, the seam 4 is formed by sewing the first fabric 2 and the second fabric 3 together from the back with the front sides facing each other.

[0021] The first fabric 2 and the second fabric 3 are made of, for example, woven fabric and / or knitted fabric. The first fabric 2 and the second fabric 3 are made of, for example, 100% synthetic polyester. Note that the thermal adhesive thread can be bonded to fabrics made of not only synthetic fibers but also natural fibers.

[0022] As shown in Figure 4, the first end 21 is located on one side in the width direction of the first fabric 2. The second end 31 is located on one side in the width direction of the second fabric 3. The first end 21 and the second end 31 are overlocked with a locking thread S1. In this embodiment, the first end 21 and the second end 31 are sewn together integrally by overlocking with the locking thread S1.

[0023] The overcasting of the first end 21 and the second end 31 is performed by, for example, a single-needle, three-thread overlock sewing machine. The multiple loops L1, L2 constituting the overcasting include a first loop L1 located on the back surface 2b of the first fabric 2 and a second loop L2 located on the back surface 3b of the second fabric 3. The first loops L1 and the second loops L2 extend continuously, adjacent to each other, along the edges 2a, 3a of the first fabric 2 and the second fabric 3.

[0024] The locking thread S1 has a first back locking thread S11 located on the back surface 2b of the first fabric 2 and a second back locking thread S12 located on the back surface 3b of the second fabric 2. The first back locking thread S11 forms a plurality of first loops L1 that are continuous in the longitudinal direction on the back surface 2b of the first fabric 2. The second back locking thread S12 forms a plurality of second loops L2 that are continuous in the longitudinal direction on the back surface 3b of the second fabric 3.

[0025] The pitch P1 of each of the first and second loops L1, L2 may be set to a value 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. When the pitch P1 is 2.0 mm, the number of stitches is 14 per 3 cm, and when the pitch P1 is 3.0 mm, the number of stitches is 22 per 3 cm. Here, the number of stitches is the number of perforations per 3 cm.

[0026] The width W1 of each of the first and second loops L1, L2 may be set to 5 mm or more and 8 mm or less, for example, 6 mm. The width W1 of each of the first and second loops L1, L2 corresponds to the swing width of the overlock machine and is the distance from the edge portions 2a, 3a of the first fabric 2 and the second fabric 3 to the end portions L11, L21 of the first and second loops L1, L2 on the opposite side of the edge portions 2a, 3a.

[0027] A needle thread S3 is arranged on the end portion L11, L21 side of each first loop L1 and each second loop L2, connecting adjacent first loops L1 and adjacent second loops L2, respectively, to form a continuous stitch in the longitudinal direction. In this embodiment, the needle thread S3 includes a right needle thread S31 located on the edge portion 2a, 3a side and a left needle thread S32 located on the opposite side to the edge portion 2a, 3a.

[0028] The needle thread S3 fixes the first and second loops L1, L2 to the first and second fabrics 2, 3 and prevents adjacent first loops L1 from separating in the longitudinal direction. The first and second loops L1, L2 are continuous in the longitudinal direction via the needle thread S3 on the end portions L11, L21 sides. The first back lock thread S11 and the second back lock thread S12 intersect with each other at the edge portion 2a. The first loops L1 and the second loops L2 are continuous in the longitudinal direction at the edge portion 2a.

[0029] Figure 3 shows the sewing process in which the first fabric 2 and the second fabric 3 are sewn together by a plain stitch after the first end 21 and the second end 31 have been overlocked. For ease of explanation, Figure 3 shows the first end 21 and the second end 31 as being offset from each other, and the overlock stitches (lock thread S1) at the first end 21 and the second end 31 are simply shown. As shown in Figure 3, the first fabric 2 and the second fabric 3 are sewn together with the sewing thread S4, with the surface 2c of the first fabric 2 and the surface 3c of the second fabric 3 facing each other and with the edges 2a, 3a of the first fabric 2 and the second fabric 3 aligned. This forms the seam 4.

[0030] 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. As shown in Figure 5, the end adhesive portion 5 is formed by first stitching the first end portion 21 and the second end portion 31 that have been overcast, then folding the second fabric 3 in the direction opposite to the direction in which the first fabric 2 stretches, and then turning down the first end portion 21 and the second end portion 31 to one side and heat-sealing them to the back surface 3b of the second fabric 3 at 100 to 200 degrees.

[0031] In the end bonded portion 5, the heat-sealed yarns Sb and Sc of the lock yarn 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 bonded portion 5 distributes adhesive 91 remaining after the heat-sealed yarns Sb and Sc of the lock yarn 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 yarns Sb and Sc have melted are sewn together with the base yarn Sa of the lock yarn S1 and bonded together with the heat-sealed yarns Sb and Sc. The end bonded portion 5 is a 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 the adhesive 91 distributed in the bonded portion lock yarn portion 51 along the lock yarn S1.

[0032] 4 and 7 , for example, the edge bonding portion 5 is disposed 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 edge bonding portion 5 roughly matches the width W1 of the first loop L1 to the second loop L2. For example, when the edges are bonded with seam tape or the like, a base material is disposed in the edge bonding portion on the opposite bonding surface of the seam tape, but in this embodiment, no base material is disposed in the edge bonding portion 5.

[0033] FIG. 7 is an image of the bonded lock yarn portion 51 and its surrounding area taken with a scanning electron microscope (SEM) (Miniscope™ 3000, manufactured by Hitachi High-Technologies Corporation). The set magnification of the SEM image is 30x. As shown in FIG. 7 , in the end bonded portion 5, the amount of the first adhesive 91 distributed in the bonded lock yarn portion 51 along the lock yarn S1 (base yarn Sa) is greater than the amount of the second adhesive 92 distributed in the other portion R. In this embodiment, the bonded lock yarn portion 51 is a region including the portion 51 where the lock yarn S1 is arranged and its vicinity 52.

[0034] 8 , the amount of adhesive 91 may be, for example, the thickness of the adhesive 91 applied to the first fabric 2 and the second fabric 3. The thickness t1 of the adhesive 91 distributed in the bonded lock yarn portion 51 is greater than the thickness t2 of the adhesive 92 distributed in the other portion R.

[0035] In this embodiment, the bonded portion locking thread portion 51 is sewn by a sewing machine. The sewing speed of the bonded portion locking thread portion 51 can be adjusted by the rotation speed of the sewing machine motor. The rotation speed of the sewing machine motor may be set to 3000 rpm or more and 8000 rpm or less, for example, 4000 rpm.

[0036] Next, a method for manufacturing the end fixing structure 1 for two sewn together fabrics 2 and 3 will be described.

[0037] As shown in Figure 5, a first fabric 2 and a second fabric 3 are prepared. The first fabric 2 and the second fabric 3 are overlapped with the front sides facing each other. A first end 21, which is an end on one side in the width direction of the first fabric 2, and a second end 31, which is an end on one side in the width direction of the second fabric 3, are overlocked with a locking thread S1 including heat-sealing threads Sb and Sc.

[0038] As shown in Fig. 5, the first end 21 and the second end 31 are stitched together with a sewing thread S4 to form a seam 4. As shown in Figs. 3 and 6, the 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 bonded portion 5, thereby obtaining an end fixed structure 1 for two sewn together fabrics 2, 3. Examples of heating methods that can be used to apply heat to the first end 21 and the second end 31 include a heat press that applies heat, pressure, and cooling, ultrasonic heating that vibrates the first end 21 and the second end 31 with ultrasonic vibrations and melts and bonds the heat-sealing threads Sb and Sc with frictional heat generated between the ends by the vibrations, and high-frequency heating that heats by potential movement at the molecular level using high-frequency energy (electromagnetic waves). Among these heating methods, an appropriate heating method may be adopted, or a combination of multiple heating methods may be adopted, taking into consideration the thickness of the fabric, the number of layers of fabric (the distance from the surface of the fabric to the fusion yarn), and production efficiency.

[0039] With the above-described configuration, the heat-fusible sewing thread S1 according to this embodiment has the following advantages.

[0040] 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 a Z twist around the outer periphery of the first heat-sealable thread Sb using an Z twist around the base thread Sa.

[0041] According to this configuration, the twist and untwist directions of the first heat-sealing thread Sb and the second heat-sealing thread Sc are opposite to each other, which reduces the likelihood of fraying or unevenness during sewing compared to when the twist directions are the same. This prevents the base thread, the first heat-sealing thread, and the second heat-sealing thread from separating, even when sewing with a sewing machine. The remaining base thread in the sewn area provides strong seams, allowing for stable sewing. In this embodiment, the twist direction of the first heat-sealing thread Sb is set to an S twist, and the twist direction of the second heat-sealing thread Sc is set to a Z twist, which reduces the likelihood of untwist when sewing with a sewing machine. In other words, from the perspective of sewability, it is preferable to set the twist direction of the first heat-sealing thread Sb to an S twist and the twist direction of the second heat-sealing thread Sc to a Z twist.

[0042] As in the embodiment, when the heat-sealable sewing thread S1 is 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 tilted on one side or both sides, by melting the first and second heat-sealable threads Sb, Sc after overlocking, the adhesive 91 distributed along the heat-sealable sewing thread S1 can fix 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 portion, which can prevent the ends from fraying due to aging, as occurs when the fabric ends are fixed only with adhesive.

[0043] After the first and second heat-sealing threads Sb, Sc are melted, the adhesive 91 is distributed along the first and second heat-sealing threads Sb, Sc. This prevents excessive distribution of the adhesive compared to when a hot-melt tape or other material is applied to the entire edge of the fabric. This prevents the fabric from hardening and increasing in weight, while maintaining a good appearance when fastening the edges of the fabric. Because the edges of the fabric are overlocked, they are seamlessly connected in the direction of extension of the locking thread S1, more effectively fastening the edges 21, 31 of the first and second fabrics 2, 3 to the main body 30 of the second fabric 3.

[0044] The weight ratio of the first heat-fusible thread Sb and the second heat-fusible thread Sc to the weight of the heat-fusible sewing thread S1 is 25% or more and 50% or less.

[0045] According to this configuration, the proportions of the first and second heat-sealing threads contained in the sewing thread can be appropriately set. For example, when the edges of two pieces of fabric are oversewn with the sewing thread and one or both pieces are oversewn, if the proportion of the heat-sealing thread contained in the sewing thread is less than 25%, the amount of molten adhesive distributed along the oversewn portion where the sewing thread is arranged is likely to be insufficient, resulting in insufficient adhesive strength or adhesive area, and the edge of the fabric is likely to peel off from the main body of the fabric.

[0046] If the proportion of the first and second heat-sealing threads contained in the sewing thread exceeds 50%, the thickness of the base thread will become thinner, assuming that the thickness of the sewing thread is constant, and the seam strength will likely be weakened.

[0047] The melting temperatures of the first and second heat-fusible yarns Sb and Sc are 100 degrees or higher and 200 degrees or lower.

[0048] According to this configuration, the melting temperatures of the first and second heat-sealing threads Sb and Sc can be appropriately set. If the melting temperature is less than 100°C, the first and second heat-sealing threads Sb and Sc may melt due to the temperature of the sewing needle, which is increased by the heat of friction between the sewing needle and the fabric during sewing. Furthermore, the first and second heat-sealing threads Sb and Sc may melt when ironed or tumble-dried after production, resulting in a decrease in 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.

[0049] The number of twists of the first and second heat-fusible yarns Sb, Sc is 450 times / m or more and 550 times / m or less.

[0050] According to this configuration, the number of twists of the first and second heat-fusible yarns Sb, Sc can be appropriately set. If the number of twists of the first and second heat-fusible yarns is less than 450 times / m, the winding of the heat-fusible yarns becomes loose and they tend to unravel. If the number of twists exceeds 550 times / m, the density of the heat-fusible yarns becomes excessive, which tends to increase costs.

[0051] The ratio of the diameter Z1 of the heat-fusible sewing thread S1 to the length Z of the major axis 61a of the thread eye 61 of the sewing needle 6 through which the heat-fusible sewing thread S1 is inserted is 0.35 to 0.9.

[0052] According to this configuration, it is possible to appropriately set 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. 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 is insufficient, making it difficult to achieve the desired 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 rises 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.

[0053] The first and second heat-bonding yarns Sb and Sc are polyamide-based heat-bonding yarns.

[0054] This structure prevents excessive rigidity and maintains texture compared to, for example, polyester or polypropylene resins. Furthermore, this structure allows bonding of not only synthetic fibers but also natural fibers, broadening the range of materials that can be bonded.

[0055] 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.

[0056] According to the present invention, 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 providing an attractive fixation of the fabric ends. Because the first end 21 and the second end 31 are overlocked, a continuous end adhesive portion 5 can be provided 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.

[0057] The first end 21 and the second end 31 are sewn together by an overlock stitch using a lock thread S1. The lock thread S1 has a first back lock thread S11 located on the back surface 2b side of the first end 21 and a second back lock thread S12 located on the back surface 3b side of the second end 31. The adhesive lock thread portion 51 is at least the portion where the second back lock thread S12 is located, tilted to one side and positioned opposite the main body portion 30.

[0058] According to this configuration, the first end 21 and the second end 31 are integrally overlocked with the locking thread S1, which simplifies the process for fixing the ends compared to when the first end 21 and the second end 31 are overlocked separately. By simply providing the 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, the first end 21 and the second end 31 can be fixed to the main body portions 20, 30, and the increase in adhesive can be suppressed compared to when an adhesive locking thread portion is also provided on the other side.

[0059] The manufacturing method of the end fixing structure 1 includes preparing a first fabric 2 having a first end 21 and a second fabric 3 having a second end 31, overstitching the first end 21 and the second end 31 with a locking thread S1 including heat-sealing threads Sb and Sc, and then stitching the first end 21 and the second end 31 together to form a seam 4, and then bending the first end 21 and the second end 31 on one side or both sides and adhering them to the main body portions 20, 30 of the first fabric 2 and / or the second fabric 3 to form an end adhesive portion 5.

[0060] According to the present invention, the first end 21 and the second end 31, which are oversewn with a locking thread S1 including thermal adhesive threads Sb and Sc, can be fixed to the main body portions 20 and 30. Compared to when a tape member such as a hot melt adhesive is applied to the entire end adhesive portion 5, excessive distribution of adhesive can be suppressed. This prevents the fabric from hardening and increasing in weight, while allowing the fabric ends to be fixed in an attractive manner.

[0061] The first end 21 and the second end 31 are sewn together by an overlock stitch using a locking thread S1. The locking thread S1 has a first back locking thread S11 located on the back surface 2b side of the first end 21 and a second back locking thread S12 located on the back surface 3b side 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 arranged opposite the main body portions 20, 30, has heat-sealing threads Sb, Sc.

[0062] According to this configuration, the first end 21 and the second end 31 are integrally overlocked with the locking thread S1, which simplifies the process for fixing the ends compared to when the first end 21 and the second end 31 are overlocked separately. At least one of the first back locking thread S11 and the second back locking thread S12, which are tilted to one side and arranged opposite the main body portions 20, 30, contains the heat-sealing threads Sb, Sc, which allows the first end 21 and the second end 31 to be fixed to the main body portions 20, 30. Compared to when the other also contains the heat-sealing threads Sb, Sc, the increase in adhesive can be suppressed.

[0063] The pitch P1 of the overlock stitch formed by the lock thread S1 is 0.5 mm or more and 3.0 mm or less.

[0064] 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., while if the pitch P1 exceeds 3.0 mm, the molten adhesive 91 distributed in the lock thread portion 51 of the adhesive portion along the lock thread S1 is likely to become discontinuous in some areas, making it difficult to prevent the first end 21 and the second end 22 from peeling off from the main body portions 20, 30.

[0065] 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 be between 3000 rpm and 8000 rpm.

[0066] This configuration allows the sewing speed to be set appropriately. If the sewing speed is less than 3,000 rpm, production efficiency decreases. 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 melt the thermal adhesive threads Sb and Sc.

[0067] In the present embodiment, the first back locking yarn S11 and the second back locking yarn S12 include heat-sealed yarns Sb and Sc, but the present invention is not limited to this. For example, the second back locking yarn S12, which is disposed opposite the back surface 3b of the main body 30 of the second fabric 3 that is laid down to one side, may include heat-sealed yarns Sb and Sc, and the first back locking 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.

[0068] In this embodiment, the end adhesive portion 5 is described as being formed by tilting the first end portion 21 and the second end portion 31 to one side and heat-sealing them to the back surface 3b of the second fabric 3, but this is not limited to this, and the end adhesive portion 5 may also be formed by tilting the first end portion 21 and the second end portion 31 to one side and heat-sealing them to the back surface 2b of the first fabric 2.

[0069] In this embodiment, the first end 21 and the second end 31 are overcast using a single-needle, three-thread lockstitch machine, but this is not limiting, and the first end 21 and the second end 31 may be overcast using a two-needle, four-thread lockstitch machine. In this case, since two needle threads S3 are used to secure the loop to the fabric and are arranged along the direction in which the fabric edge extends, one of the two needle threads may be used to substitute for the base stitch of the suture thread S4, as shown by the two-dot chain line in Figure 6.

[0070] In this embodiment, a configuration has been described in which the 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 to form the stitching portion 4, but this is not limited to this, and the stitching portion 4 (sewn thread S4) may not be provided.

[0071] In this embodiment, the first end 21 and the second end 31 are configured to be integrally overlocked, but this is not limited to this. For example, as shown in FIG. 9, the 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.

[0072] More specifically, the fabric 102 may have a first end 121 of the first fabric 102 oversewn with a first locking thread S5, a second end 131 of the second fabric 103 oversewn with a second locking thread S6, a stitched portion 104 where the first end 121 and the second end 131 are stitched together with a sewing thread S7, and end bonding portions 105, 105 where the folded first end 121 and the 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.

[0073] The first lock thread S5 has a first back side thread S51 located on the back surface 102b side of the first end 121 and a first front side thread S52 located on the front surface 102c side. The second lock thread S6 has a second back side thread S61 located on the back surface 103b side of the second end 131 and a second front side thread S62 located on the front surface 103c side.

[0074] 7 and 8, the amount of adhesive 91 distributed in the bonded lock thread portion 51 along the first lock thread S5 and the second lock thread S6 is greater than the amount of adhesive 92 distributed in the other portion R. The bonded lock thread portion 51 may be at least the portion where the first back side thread S51 and the second back side thread S61, which are arranged opposite the main body portions 120 and 130, are arranged.

[0075] The configuration of the end fixing structure 101 shown in FIG. 9 provides the following effects.

[0076] The lock thread has a first lock thread S5 for overlocking the first end 121 and a second lock thread S6 for overlocking the second end 131. The first lock thread S5 has a first back side thread S51 located on the back surface 102b side of the first end 121 and a first front side thread S52 located on the front surface 102c side. The second lock thread S6 has a second back side thread S61 located on the back surface 103b side of the second end 131 and a second front side thread S62 located on the front surface 103c side. The end bonding portion 105 has both the first end 121 and the second end 131 bent down and bonded to the main body portions 120 and 130, respectively. The bonding portion lock thread portion 51 is a portion where at least the first back side thread S51 and the second back side thread S61 arranged opposite the main body portions 120 and 130 are arranged.

[0077] According to this configuration, the first end portion 121 and the second end portion 131 can be bonded to the main body portions 120 and 130, respectively, by the adhesive 91 distributed in the bonded lock thread portion 51.

[0078] The lock thread has a first lock thread S5 for overlocking the first end 121 and a second lock thread S6 for overlocking the second end 131. The first lock thread S5 has a first back side thread S51 located on the back surface 102b side of the first end 121 and a first front side thread S52 located on the front surface 102c side. The second lock thread S6 has a second back side thread S61 located on the back surface 103b side of the second end 131 and a second front side thread S62 located on the front surface 103c side. The end bonding portion 105 has both the first end 121 and the second end 131 bent down and bonded to the main body portions 120 and 130, respectively. At least the first back side thread S51 and the second back side thread S61, which are arranged opposite the main body portions 120 and 130, have heat-sealed threads Sb and Sc.

[0079] According to this configuration, the first end portion 121 and the second end portion 131 can be bonded to the main body portions 120, 130 by the heat-sealing threads Sb, Sc contained in the first back side threads S51 and the second back side threads S61, which are arranged opposite each other on the main body portions 120, 130, out of the first locking threads S5 and the second locking threads S6 of the laid-down first end portion 121 and the second end portion 131. Compared to when the first front side threads S52 and the second front side threads S62 also contain the heat-sealing threads Sb, Sc, an increase in adhesive can be suppressed.

[0080] Although this embodiment shows an example of overlock stitching using a lockstitch machine, other sewing methods such as lockstitching and zigzag stitching can also be applied. After sewing, problems such as thread fraying can be solved by subsequent thermocompression bonding. In the case of lockstitching, the motor rotation speed is preferably 3000 rpm or more and 5000 rpm or less.

[0081] Furthermore, for example, when the heat-fusible sewing thread S1 is used to sew two pieces of waterproof fabric, the sewn portion sewn with the heat-fusible sewing thread S1 can be sewn by melting the first and second heat-fusible threads Sb and Sc after sewing, so that the needle holes formed by the sewing are closed by the first and second heat-fusible threads Sb and Sc, and the base thread Sa can be sewn. This prevents water from entering through the needle holes while suppressing peeling due to aging, which occurs when two pieces of waterproof fabric are bonded together with adhesive or the like. Furthermore, 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.

[0082] The heat-fusible sewing thread S1 of the present invention may be used to sew two or more layers of fabric used in clothing, hats, bags, gloves, tents, tarps, sleeping bags, sheets, umbrellas, etc., or may be used to sew quilted parts having two or more layers of fabric and filling, such as down or bedding.

[0083] The heat-fusible sewing thread S1 according to the present invention is not limited to the configuration of the above-described embodiment, and various modifications are possible.

[0084] Second Embodiment Next, a waterproof joint structure using heat-sealable sewing thread will be described. As shown in Fig. 10 , 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 that stitches the first end portion 1021 to the second end portion 1031 together. In this embodiment, the stitching portion 1005 stitches the first end portion 1021 to the second end portion 1031 together by a plain stitch.

[0085] "Plain seam" 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, as described in JIS L0122. 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.

[0086] 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. For example, the first fabric 1002 and the second fabric 1003 can be made of a fabric with a water pressure resistance of 2,000 mm or more.

[0087] As shown in FIG. 11 , the first end 1021 is located at at least one end in the width direction of the first fabric 1002. The first end 1021 is overcast with a first locking thread S1001. In this embodiment, the overcasting of the first end 1021 is performed by, for example, overcasting using a single-needle, three-thread locking machine. The multiple first loops L1001, L1002 constituting the overcasting include a first front loop L1001 located on the front surface (one side) 1002b of the first fabric 1002 and a first back loop L1002 located on the back surface (the other side) 1002c. The first front loop L1001 and the first back loop L1002 extend continuously along the edge 1002a of the first fabric 1002.

[0088] The first lock thread S1001 has a first one side thread S1011 located on the front surface 1002b of the first fabric 1002 and a first other side thread S1012 located on the back surface 1002c. The first one side thread S1011 forms a plurality of first front loops L1001 that are continuous in the longitudinal direction on the front surface 1002b of the first fabric 1002. The first other side thread S1012 forms a plurality of first back loops L1002 that are continuous in the longitudinal direction on the back surface 1002c of the first fabric 1002.

[0089] 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. When the pitch P1001 is 2.0 mm, the number of stitches is 14 per 3 cm, and when the pitch P1001 is 3.0 mm, the number of stitches is 22 per 3 cm. Here, the number of stitches is the number of perforations per 3 cm.

[0090] The width W1001 of each of the first loops L1001, L1002 may be set to 5 mm or more and 8 mm or less, for example, 6 mm. The width W1 of each of the first loops L1001, L1002 corresponds to the swing width of the overlock machine, and is the distance from the edge 1002a of the first fabric 1002 to the end L1011, L1021 of each of the first loops L1001, L1002 on the side opposite the edge 1002a of the first fabric 1002.

[0091] A needle thread S1003 is arranged on the end portions L1011 and L1021 of each of the first front loops L1001 and each of the first back loops L1002, connecting the adjacent first front loops L1001 and first back loops L1002 to form continuous stitches in the longitudinal direction. In this embodiment, 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.

[0092] The needle thread S1003 fixes the plurality of first loops L1001, L1002 to the first fabric 1002 and prevents adjacent first loops L1001 from separating in the longitudinal direction. The plurality of first loops L1001, L1002 are continuous in the longitudinal direction via the needle thread S1003 on the end portions L1011, L1021 side. The first one-side thread S1011 and the first other-side thread S1012 intersect with each other at the edge portion 1002a. The plurality of first front loops L1001 and first back loops L1002 are continuous in the longitudinal direction at the edge portion 1002a.

[0093] The second end 1031, like the first end 1021, is located at an end on at least one widthwise side of the second fabric 1003. The second end 1031 is overlocked with a second locking thread S1002. Since the second end 1031 has the same configuration as the first end 1021, detailed description thereof will be omitted, and the configuration of the second end 1031 will be indicated in parentheses in Figure 11.

[0094] As shown 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. Similar to the first lock thread S1001, the second lock thread S1002 has a swing width W1001 and a pitch P1001 set for the second loops L1003, L1004.

[0095] Fig. 12 shows a sewing process in which the first fabric 1002 and the second fabric 1003 are sewn together by a plain stitch after the first end 1021 and the second end 1031 have been overlocked. Fig. 12 simply shows the overlock stitches (first locking thread S1001 and second locking thread S1002) of the first end 1021 and the second end 1031. As shown in Fig. 12, the first fabric 1002 and the second fabric 1003 are arranged such 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 a sewn portion 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, and 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.

[0096] Figure 13 shows a cross section taken along line XIII-XIII in the sewing step of Figure 12. As shown in Figure 13, a sewing thread S1004 is arranged in the sewing portion 1005. The sewing thread S1004 has 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.

[0097] The intersection point S1040 of the first suture thread S1041 and the second suture thread S1042 is located at the center in the thickness direction of the overlapping first fabric 1002 and second fabric 1003. In other words, the intersection point S1040 is located at the center in the thickness direction of the needle hole 1051 of the first fabric 1002 and the second fabric 1003 formed during sewing. The position of the intersection point S1040 is set by the thread tension of the sewing machine.

[0098] 14 is an enlarged schematic view showing the first locking thread S1001 alone. As shown in FIG. 14, in this embodiment, the first locking thread S1001 is composed of threads including heat-fusible threads Sb and Sc.

[0099] The first lock yarn S1001 is formed by spirally winding heat-fusible yarns Sb and Sc containing heat-fusible components around a base yarn Sa containing no heat-fusible components. In this embodiment, the base yarn Sa is formed, for example, of a polyester two-ply yarn or a three-ply twisted filament yarn (e.g., a filament yarn having a thickness of 75 dtex to 80 dtex, formed by three-ply twisting a filament yarn consisting of 24 single yarns). The heat-fusible yarns Sb and Sc may be polyamide-based fusible yarns, for example, a filament yarn having a thickness of 75 dtex to 80 dtex, formed by 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), and a yarn having a length of 10,000 m and a weight of 1 g is called 1 dtex. The ratio of the heat-fusible yarns Sb and Sc to the weight of the first lock yarn S1001 may be set to 25% or more and less than 50%, and is set to, for example, 39%.

[0100] The melting temperature of the heat-sealing thread Sb may be set to 100° C. or higher and 200° C. or lower, for example, 120° C. or 130° C. While the first locking thread S1001 has been described in Fig. 14, the second locking thread S1002, needle thread S1003, and suture thread S1004 also have a base thread Sa and a heat-sealing thread Sb, similar to the first locking thread S1001.

[0101] As shown in Figure 14, the fusion yarns Sb and 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. From the viewpoint of sewability, the twist directions of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc relative to the base yarn Sa are preferably opposite. In this embodiment, 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 numbers of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to 450 turns / m or more and 550 turns / m or less, and in this embodiment, the twist number is set to approximately 500 turns / m. The twist angle α of the lower heat fusion yarn Sb may be set to 10 degrees or more and 30 degrees or less, and in this embodiment, it is set to approximately 20 degrees. The twist angle β of the upper heat-fusion yarn may be set to between 10 degrees and 30 degrees, and in this embodiment is set to approximately 20 degrees. In this embodiment, each of the twist angles α and β is the angle between the axis X1 of the base yarn Sa and the lower heat-fusion yarn Sb or the upper heat-fusion yarn Sc.

[0102] FIG. 15 is an enlarged cross-sectional view schematically illustrating the area around the eyelet 1061 of the sewing needle 1006 that sews the first fabric 1002 and the second fabric 1003 together. As shown in FIG. 15 , the eyelet 1061 of the sewing needle 1006 is generally elliptical, having a major axis 1061 a and a minor axis 1061 b. 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, the eyelet 1061 is preferably large relative to the width d1 of the sewing needle 1006. For example, a sewing machine needle size 14 manufactured by Organ Needle Co., Ltd. may be used, in which the width d1 of the sewing needle 1006 is 0.8 mm, and the eyelet 1061 has a major axis 1061 a length of 0.8 mm and a minor axis 1061 b length of 0.3 mm. In this embodiment, the width d1 of the sewing needle 1006 is the width of the portion of the sewing needle 1006 in the longitudinal direction where the minor axis 1061b is located.

[0103] As shown in Figure 15, the diameter Z1 of the first locking thread S1001, indicated by the two-dot chain line, may be set to 0.35 to 0.9 times the length Z of the major axis 1061a of the thread eye 1061 of the sewing needle 1006, for example, 0.5 times. While Figure 15 describes the sewing needle 1006 for the first locking thread S1001, the sewing needles for the second locking thread S1002 and suture thread S1004 have the same configuration as the sewing needle 1061 for the first locking thread S1001, and therefore detailed description thereof will be omitted.

[0104] Figure 16 is a cross-sectional schematic diagram taken along line XVI-XVI in Figure 10, showing the end bonded portion 1004 and the sewn portion 1005. As shown in Figure 16, the end bonded portion 1004 is formed by stitching the first end 1021 and the second end 1031 together, folding the second fabric 1003 back in the direction opposite to the direction in which the first fabric 1002 extends, and then turning down the first end 1021 and the second end 1031 to one side, heat-sealing the first end 1021 and the second end 1031 to each other and heat-sealing the first end 1021 and the second end 1031 to the back surface 1003c of the second fabric 1003 at a temperature of 100 to 200 degrees.

[0105] In the end bonding portion 1004, the heat-sealed yarns Sb, Sc of the first locking yarn S1001 and the second locking yarn 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 yarn S1001 and the second locking yarn S1002 have melted. More specifically, as shown in FIG. 17 , after the heat-sealed yarns Sb, Sc have been thermally melted, the first end 1021 and the second end 1031 are sewn together with the base yarn Sa of the first locking yarn S1001 and the second locking yarn S1002 and are also bonded together with the heat-sealed yarns Sb, Sc. In this embodiment, the end adhesive portion 1004 is a portion where the first end 1021 and the second end 1031 are adhered to each other by adhesive 1091 distributed in the adhesive portion lock thread portion 1041 along the first and second lock threads S1001 and S1002.

[0106] As shown in FIGS. 11 and 17 , for example, the edge bonded portion 1004 is disposed between the edge portions 1002a, 1003a of the first fabric 1002 and the second fabric 1003 and the ends L1011, L1021, L1031, and L1041 of the first loops L1001, L1002 and the second loops L1003, L1004. The width of the edge bonded portion 1004 is generally the same as the width W1001 of the first loops L1001, L1002 and the second loops L1003, L1004. For example, when the edges are bonded with seam tape or the like, a base material is disposed on the opposite side of the seam tape at the edge bonded portion. However, in this embodiment, no base material is disposed at the edge bonded portion 1004. This prevents the garment from becoming stiffer due to the increased rigidity of the base material, as occurs when the edges of garments, etc., are bonded with seam tape or the like, resulting in a less comfortable garment. Furthermore, when the ends of clothing or the like are glued together using seam tape or the like, the width of the end adhesive portion must be set larger than the loop width W1001 in order to prevent water from entering through the seams, so the area in which the base material is placed is wider, which makes it more likely that the rigidity will increase; however, since no base material remains at the end adhesive portion 1004 and the width of the end adhesive portion 1004 roughly matches the loop width W1001, it is easier to prevent the rigidity from increasing.

[0107] FIG. 17 is an image of the bonded lock thread portion 1051 and its surrounding area taken with a scanning electron microscope (SEM) (Miniscope™ 3000, manufactured by Hitachi High-Technologies Corporation). The set magnification of the SEM image is 30x. As shown in FIG. 17 , in the end bonded portion 1004, the amount of adhesive 1091 distributed in the bonded lock thread portion 1041 along the first lock thread S1001 and the second lock thread S1002 (base thread Sa) is greater than the amount of adhesive 1092 distributed in the other portion R. In this embodiment, the bonded lock thread portion 1041 is a region including the portion 1041 where the first and second lock threads S1001 and S1002 are arranged and its vicinity 1042.

[0108] 18 , the amount of adhesive 1091, 1092 may be, for example, the thickness of adhesive 1091, 1092 laminated on the first fabric 1002 and the second fabric 1003. A thickness t1 of the adhesive 1091 distributed in the adhesive lock thread portion 1041 is thicker than a thickness t2 of the adhesive 1092 distributed in the other portion R.

[0109] The heat-sealing threads Sb and Sc of the suture thread S4 are melted at the same time as the first end 1021 and the second end 1031 are heat-sealed together. When the heat-sealing threads Sb and Sc of the suture thread S1004 are melted, the heat-sealing threads Sb and Sc close the needle holes 1051 formed during the base stitching, and the sewn portion 1005 is sewn together with the base thread Sa, as shown in FIG.

[0110] In this embodiment, the adhesive locking thread portion 1041 and the suture thread portion 1052 are sewn by a sewing machine. The sewing speed of the adhesive locking 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 3000 rpm or more and 8000 rpm or less, and is set to, for example, 4000 rpm.

[0111] Next, a method for manufacturing the waterproof joint structure 1001 will be described.

[0112] As shown in Figure 11, a waterproof first fabric 1002 and a second fabric 1003 are prepared. A first end 1021, which is an end on one side in the width direction of the first fabric 1002, is overlocked with a first locking thread S1001 including thermal fusion threads Sb and Sc. A second end 1031, which is an end on one side in the width direction of the second fabric 1003, is overlocked with a second locking thread S1002 including thermal fusion threads Sb and Sc.

[0113] 12 , 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 including thermal fusion threads Sb and Sc to form a seam 1005. As shown in FIGS. 10 and 16 , the first end 1021 and the second end 1031 are laid down to one side, and 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 bonded to the back surfaces 1002 c and 1003 c 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 are melted to seal the pinholes 1051 with adhesive, thereby obtaining a waterproof joint structure 1001. The heating method for applying heat to the first end 1021 and the second end 1031 can be, 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 vibration, high-frequency heating that heats by potential movement at the molecular level using high-frequency energy (electromagnetic waves), etc. Among these heating methods, an appropriate heating method may be adopted, taking into consideration the fabric thickness, the number of layers of fabric (the distance from the fabric surface to the fusion threads), and production efficiency, or a combination of multiple heating methods may be adopted.

[0114] With the above-described configuration, the waterproof joint structure 1001 according to this embodiment has the following advantages.

[0115] The waterproof joint structure 1001 has 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 together, and a stitching portion 1005 where the first end 1021 and the second end 1031 are sewn together with a suture thread and where the needle hole 1051 of the suture thread S1004 is sealed with adhesive.

[0116] According to the present invention, the first end 1021 and the second end 1031 are bonded by the end bonding portion 1004, which prevents water from penetrating from the front surfaces 1002b and 1003b of the first fabric 1002 and the second fabric 1003 to the back surfaces 1002c and 1003c through the gap between the first fabric 1002 and the second fabric 1003. The first fabric 1002 and the second fabric 1003 are sewn together by the stitching portion 1005, which prevents peeling due to aging, which occurs when the first fabric 1002 and the second fabric 1003 are bonded together with an adhesive or the like. The needle hole 1051 of the suture thread S1004 is sealed with adhesive, which prevents water from penetrating through the needle hole 1051. Since the amount of adhesive 1094 distributed in the other parts R is reduced compared to the amount of adhesive distributed in the end adhesive parts 1004 and / or the stitching parts 1005, excessive distribution of adhesive can be prevented, and an increase in the weight of the fabric can be prevented.

[0117] The first fabric 1002 and the second fabric 1003 are sewn together by a plain stitch, so that the end adhesive portion 1004 is not exposed on the surfaces 1002b and 1003b, resulting in an excellent aesthetic appearance.

[0118] The first end 1021 and the second end 1031 are overlocked with a first locking thread S1001 and a second locking thread S1002, respectively, and the end bonding 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 locking thread portion 1041 along the first and second locking threads S1001, S1002, and in the end bonding portion 1004, the amount of adhesive 1091 distributed in the bonded portion locking thread portion 1041 is greater than the amount of adhesive 1092 distributed in the other portion R.

[0119] According to this configuration, the first end 1021 and the second end 1031 are bonded together by the adhesive 1091 distributed in the bonded lock thread portion 1041, thereby preventing water from entering between the first end 1021 and the second end 1031. Because the first end 1021 and the second end 1031 are overlocked, a continuous, uninterrupted end adhesive portion 1004 can be provided along the first end 1021 and the second end 1031, where the first lock thread S1001 and the second lock thread S1002 are continuous, thereby more effectively preventing water from entering between the first fabric 1002 and the second fabric 1003. Because the amount of adhesive 1092 distributed in the other portion R is less than the amount of adhesive 1091 distributed in the bonded lock thread portion 1041, excessive distribution of adhesive can be prevented compared to when a tape material such as a hot melt is applied to the entire end adhesive portion 1004. This prevents the fabric from hardening and increasing in weight, while allowing the edges of the fabric to be fixed in an attractive manner.

[0120] 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 of the first fabric 1002. 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 a portion where at least the first one-side thread S1011 and the second one-side thread S1021 are arranged.

[0121] According to this configuration, the 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 middle 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.

[0122] The waterproof joint structure is manufactured by overlocking a first end 1021 of a first fabric 1002 with a first locking thread S1001 including thermal fusion threads Sb and Sc, overlocking a second end 1031 of a second fabric 1003 with a second locking thread S1002 including thermal fusion threads Sb and Sc, sewing the first end 1021 and the second end 1031 together with a suture thread S1004 including thermal fusion threads Sb and Sc to form a seamed portion 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 adhesive portion 1004, and melting the suture thread S1004 of the seamed portion 1005 to close the needle hole 1051.

[0123] According to the present invention, the first end 1021 and the second end 1031, which are overlocked with the first locking thread S1001 and the second locking thread S1002 including the thermal adhesive threads Sb and Sc, are bonded to form the end bonded portion 1004, which prevents water from penetrating from the front surfaces 1002b and 1003b of the first fabric 1002 and the second fabric 1003 to the back surfaces 1002c and 1003c through the gap between the first fabric 1002 and the second fabric 1003. The first fabric 1002 and the second fabric 1003 are sewn together by the seam 1005, which prevents peeling due to deterioration over time, as occurs when the first fabric 1002 and the second fabric 1003 are bonded together with an adhesive or the like. By melting the suture thread S1004 including the heat-fusible threads Sb and Sc, the needle holes 1051 formed in the first fabric 1002 and the second fabric 1003 during sewing can be sealed with adhesive, preventing water from entering through the needle holes 1051. Since the amount of adhesive 1094 distributed in the other portion R is reduced compared to the amount of adhesive distributed in the end adhesive portion 1004 and / or the stitched portion 1005, excessive distribution of adhesive can be prevented, and an increase in the weight of the fabric can be suppressed.

[0124] 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, and at least the first one-side thread S1011 and the second one-side thread S1021 include heat-sealing threads Sb, Sc.

[0125] According to this configuration, the first end 1021 and the second end 1031 are bonded together by the heat-sealed threads Sb and Sc contained in the first one-side thread S1011 and the second one-side thread S1021 arranged on the first opposing surface 1002b and the 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.

[0126] The pitch P1001 of the overlock stitches 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.

[0127] This configuration allows the overlock pitch P1001 to 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 lock thread portion 1041 of the adhesive portion along the first lock thread S1001 and / or the 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.

[0128] The first locking thread S1001, the second locking thread S1002, and the suture thread S1004 are constructed by spirally winding heat-fusible threads Sb and Sc containing a heat-fusible component around a base thread Sa containing no heat-fusible component.

[0129] According to this configuration, even when the heat-sealed threads Sb and Sc are melted after heat welding, the base thread Sa remains in the end bonding portion 1004 and the stitching portion 1005, thereby preventing fraying and peeling due to deterioration over time, as occurs when the end bonding portion 1004 and the stitching portion 1005 are bonded with an adhesive or the like.

[0130] The weight ratio of the heat-fusible threads Sb and Sc to the weight of the first locking thread S1001, the second locking thread S1002, and the suture thread S1004 is 25% or more and 50% or less.

[0131] This configuration allows for appropriate setting of the proportions of the heat-sealing yarns Sb and Sc contained in the first locking yarn S1001, the second locking yarn S1002, and the suture thread S1004. If the proportions of the heat-sealing yarns Sb and Sc contained in the first locking yarn S1001 and / or the second locking yarn S1002 are less than 25%, the amount of molten adhesive 1009 distributed in the locking yarn portion 1041 of the adhesive joint along the first locking yarn S1001 and / or the second locking yarn S1002 is likely to be insufficient, resulting in insufficient adhesive strength or adhesive area, and making it difficult to prevent water penetration from between the first fabric 1002 and the second fabric 1003.

[0132] If the proportion of heat-sealing threads Sb and Sc contained in the suture thread S1004 is less than 25%, the amount of adhesive 1009 is likely to be insufficient, and the needle holes 1051 formed in the first fabric 1002 and the second fabric 1003 during sewing cannot be sealed, making it difficult to prevent water from entering through the needle holes 1051.

[0133] If the thickness of the first locking thread S1001, the second locking thread S1002, and / or the suture thread S1004 is set to a predetermined thickness that will pass through the thread eye 1061 of a sewing needle of a sewing machine or the like, if the proportion of the heat-sealing threads Sb, Sc contained in the first locking thread S1001, the second locking thread S1002, and / or the suture thread S1004 exceeds 50%, the thickness of the base thread Sa will become thinner, and the seam strength will likely be weakened.

[0134] Conversely, if the thickness of the base thread Sa is constant, the thickness of the first lock thread S1001, the second lock thread S1002, and / or the suture thread S1004 increases, and the thread hole 1061 through which the first lock thread S1001, the second lock thread S1002, and / or the suture thread S1004 is passed becomes larger. As a result, the thickness of the sewing needle 1006 tends to increase as the thread hole 1061 expands. Therefore, the needle hole 1051 formed in the first fabric 1002 and the second fabric 1003 during sewing becomes larger, making it difficult to seal the needle hole 1051 with the adhesive 1093, which may make it difficult to prevent water from entering through the needle hole 1051.

[0135] The melting temperature of the thermal adhesive yarns Sb and Sc is 100 degrees or more and 200 degrees or less.

[0136] This configuration allows the melting temperature of the thermal adhesive threads Sb and Sc to be appropriately set. If the melting temperature is less than 100°C, the thermal adhesive threads Sb and Sc may melt due to the temperature of the sewing needle 1006, which is increased by frictional heat between the sewing needle 1006 and the fabric during sewing. Furthermore, the thermal adhesive threads Sb and Sc may melt when ironed or tumble dried after use, resulting in a decrease in 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.

[0137] The suture thread S1004 has a first suture thread S1041 located on the back surface 1002c of the first end 1021 and a second suture thread S1042 located on the back surface 1002c of the second end 1031, and the intersection point S1040 of the first suture thread S1041 and the second suture thread S1042 is set to be located in the center of the thickness direction of the overlapping first fabric 1002 and second fabric 1003.

[0138] According to this configuration, compared to when the intersection S1040 of the first suture thread S1041 and the second suture thread S1042 is positioned biased toward the first fabric 1002 or the second fabric 1003, it is easier to evenly seal the needle holes 1051 formed in the first fabric 1002 and the second fabric 1003 with the adhesive 1093. For example, when the intersection S1040 is biased to one side, the adhesive is likely to leak out of the needle holes 1051 on one side, and there is insufficient adhesive 1093 on the other side, making it impossible to sufficiently seal the needle holes 1051, and this may make it difficult to obtain a waterproof effect.

[0139] 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 eyelet 1061 of the sewing needle 1006 is 0.35 to 0.9.

[0140] This configuration allows the ratio of the diameter Z1 of the first lock thread S1001, the second lock 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 to be appropriately set. If the ratio of the diameter Z1 is less than 0.35, the thickness of the first lock thread S1001, the second lock thread S1002, and / or the suture thread S1004 will be insufficient, making it difficult to achieve the desired sewing strength. If the ratio of the diameter Z1 to the major axis 1061a exceeds 0.9, frictional heat generated between the thread hole 1061 and the thread being inserted may increase the temperature of the sewing needle 1006, causing the thermal fusion threads Sb and Sc to melt. Given a constant thickness and diameter Z1 of the sewing needle 1006, if the ratio of the diameter Z1 is less than 0.35, the thread hole 1061 will be relatively large, reducing the strength of the sewing needle 1006. If the diameter Z1 is kept constant while maintaining the strength of the sewing needle 1006, when the ratio of the diameter Z1 exceeds 0.9 times, the thickness of the sewing needle 1006 increases, the needle hole 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 needle hole 1051, making it difficult to prevent water from entering through the needle hole 1051.

[0141] The sewing speed of the first locking thread S1001, the second locking thread S1002, and the suture thread S1004 can be adjusted by the rotation speed of the sewing machine motor (not shown), which is set to be between 3000 rpm and 8000 rpm.

[0142] This configuration allows the sewing speed to be set appropriately. If the sewing speed is less than 3,000 rpm, production efficiency decreases. If the sewing speed exceeds 8,000 rpm, the temperature of the sewing needle 1006 is likely to rise due to frictional heat between the sewing needle 1006 and the fabric during sewing, and the temperature rise of the sewing needle 1006 may melt the thermal adhesive threads Sb and Sc.

[0143] In the present embodiment, the end adhesive portion 1004 is described as being configured by bonding the first end 1021 and the second end 1031 with adhesive 1009 distributed in the bonded lock thread portion 1041 along the first lock thread S1001 and the second lock thread S1002. However, as in the first modified example shown in FIG. 19 , the end adhesive portion 1104 may be configured by an adhesive material such as hot melt H1 disposed between the first end 1121 and the second end 1131. In this case, the first lock thread S1101 and the second lock thread S1102 may be configured only with the base thread Sa. With this configuration, the adhesive portion 1104 can bond the first end 1121 and the second end 1131, thereby preventing water from entering between the first fabric 1102 and the second fabric 1103. As in the above-described embodiment, 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 also prevents water from entering through the pinhole in the seam 1105. Furthermore, by arranging 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. In this embodiment, the hot melts H1 and H2 are made of a thermoplastic resin or the like.

[0144] 20 , 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. In other words, 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. In this case, the first other side thread S1212 of the first lock thread S1201 may be formed with a thread not containing heat-sealing threads Sb and Sc.

[0145] In this embodiment, the first end 1021 and the second end 1031 are overcast by a single-needle, three-thread lockstitch machine, but the present invention is not limited to this, and the first end 1021 and the second end 1031 may be overcast by a two-needle, four-thread lockstitch machine. In this case, since two needle threads S1003 are arranged along the direction in which the end of the fabric extends and fix the loop to the fabric, one of the two needle threads may be used to substitute for the base stitch of the suture thread S1004, as shown by the two-dot chain line in Fig. 20.

[0146] In the present embodiment, an example has been described in which the end bonded portion 1004 is configured by bonding the first end 1021 and the second end 1031 with adhesive 1009 distributed in the bonded end lock thread portion 1041 along the first lock thread S1001 and the second lock thread S1002. However, as in a third modified example shown in Fig. 21 , the end bonded portion 1304 may be configured by an ultrasonically fused portion in which the first fabric 1302 and the second fabric 1003 are melted and joined to bond the first end 1321 and the second end 1331 without using adhesive. With this configuration, the ultrasonically fused portion 1304 can bond the first end 1321 and the second end 1331, thereby preventing water from entering between the first fabric 1302 and the second fabric 1003. As in the above-described embodiment, the first end 1321 and the second end 1331 are sewn together with a sewing thread S1304 including thermal adhesive threads Sb and Sc, which also prevents water from entering through the pinhole in the seam 1305. Furthermore, by arranging hot melt H3 on the back surface 1303c of the second end 1331, the first end 1321 and the second end 1331 can be adhered to the back surface 1303c of the second fabric 1003 when they are folded to one side. The first end 1321 and the second end 1331 may be ultrasonically bonded to the back surface 1303c of the second fabric 1003 without using hot melt H3.

[0147] The manufacturing method of the waterproof joint structure 1301 includes 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 in an overlapping state 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 sutured portion 1305, and melting the suture thread S1004 of the sutured portion 1305 to close the needle hole 1351.

[0148] In this embodiment, a configuration has been described in which the first one-side thread S1011, the first other-side thread S1012, the second one-side thread S1021, the second other-side thread S1022, the first suture thread S1041, and the second suture thread S1042 include heat-sealed threads Sb and Sc, but this is not limited to this. For example, the first one-side thread S1011 and the second one-side thread S1021, which are arranged opposite each other at the first end 1021 and the second end 1031, the first suture thread S1041, and the second suture thread S1042 may be configured to include heat-sealed threads Sb and Sc.

[0149] In the present embodiment, the first fabric 1002 and the second fabric 1003 are sewn together by a plain stitch, but this is not limiting. The first fabric 1402 and the second fabric 1403 may be overcast at the first end 1421 and the second end 1431 with first and second locking threads S1401 and S1402, as in the fourth modified example shown in Fig. 22 , and the first fabric 1402 and the second fabric 1403 may be sewn together with a suture thread S1404 by overlapping the front surface 1402b of the first end 1421 with the back surface 1403c of the second end 1431. In this case, the first locking thread S1401, the second locking thread S1402, and the suture thread S1404 may be configured to include heat-sealing threads Sb and Sc.

[0150] Furthermore, as in a fifth modified example shown in FIG. 23 , the first end 1521 and the second end 1531 may be bonded with an adhesive member such as hot melt H5 disposed between the first end 1521 and the second end 1531. In this case, the suture thread S1504 may be configured to include heat-sealing threads Sb and Sc, and the first locking thread S1501 and the second locking thread S1502 may be configured with, for example, a base thread Sa without including the heat-sealing threads Sb and Sc.

[0151] The waterproof joint 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.

[0152] When the waterproof joint structure 1001 is applied to clothing such as rainwear, it is preferable that the waterproof joint structure 1001 be positioned to avoid areas that are likely to be exposed to rain when worn, such as the tops of the shoulders or the collar. Furthermore, it is preferable that the waterproof joint structure 1001 be positioned to avoid areas that are subject to pressure, such as the elbows, knees, and buttocks.

[0153] When the first end 1021 and the second end 1031 are tilted to one side, it is preferable to tilt the first end 1021 and the second end 1031 in the direction opposite to the direction of water intrusion indicated by arrow A, as shown in Figure 16.

[0154] The waterproof joint structure 1001 of the present invention was applied to clothing, and a waterproofing test was 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, working outdoors, etc. in the rain). The waterproofing test was performed by having a mannequin or a test subject wear the 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 checking whether water had penetrated into the interior of the mannequin or test subject.

[0155] 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 could not withstand rain and outdoor rainwear such as hard shells had a tape-type joint structure, making them stiff and expensive.

[0156] The waterproof joint structure 1001 of the present invention is not limited to the configuration of the above-described embodiment, and various modifications are possible.

[0157] [Third Embodiment] Next, an end fixing structure using heat-fusible sewing thread will be described. 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-fusible sewing thread according to one embodiment of the present invention. As shown in Fig. 24, the end fixing structure 2001 according to the present invention includes a first fabric 2002 having a first end 2021, a second fabric 2003 having a second end 2031, a locking thread S2001 that overlocks the first end 2021 and the second end 2031, a sewn portion 2004 where the first end 2021 and the second end 2031 are sewn together, and an end bonding portion 2005 where the first end 2021 and the second end 2031 are turned down and bonded to a main body portion 2030 of the second fabric 2003. In this embodiment, the seam 2004 is formed by sewing the first fabric 2002 and the second fabric 2003 together with a plain stitch.

[0158] "Plain seam" 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, as described in JIS L0122. In other words, the seam 2004 is formed by sewing the first fabric 2002 and the second fabric 2003 together from the back with the front sides facing each other.

[0159] 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 the thermal adhesive thread can be bonded to fabrics made of not only synthetic fibers but also natural fibers.

[0160] 25, 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. In this embodiment, the first end 2021 and the second end 2031 are sewn together integrally by overlocking with the locking thread S2001.

[0161] The overcasting of the first end 2021 and the second end 2031 is performed by, for example, a single-needle, three-thread overlock sewing machine. The multiple loops L2001, L2002 constituting the overcasting include a first loop L2001 located on the back surface 2002b of the first fabric 2002 and a second loop L2002 located on the back surface 2003b of the second fabric 2003. The first loops L2001 and the second loops L2002 extend continuously and adjacent to each other along the edges 2200a, 2003a of the first fabric 2002 and the second fabric 2003.

[0162] The lock thread S2001 includes 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 2003. 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.

[0163] The pitch P2001 of each of the first and second loops L2001, L2002 may be set to a value between 0.5 mm and 3.0 mm, and in this embodiment, it 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. When the pitch P2001 is 2.0 mm, the number of stitches is 14 per 3 cm, and when the pitch P2001 is 3.0 mm, the number of stitches is 22 per 3 cm. Here, the number of stitches refers to the number of perforations per 3 cm.

[0164] The width W1 of each of the first and second loops L2001, L2002 may be set to 5 mm or more and 8 mm or less, for example, 6 mm. The width W2001 of each of the first and second loops L2001, L2002 corresponds to the swing width of the overlock machine and is the distance from the edge portions 2002a, 2003a of the first fabric 2002 and the second fabric 2003 to the end portions L2011, L2021 on the opposite side of the edge portions 2002a, 2003a of each of the first and second loops L2001, L2002.

[0165] A needle thread S2003 is 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 to form continuous stitches in the longitudinal direction. In this embodiment, the needle thread S2003 includes a right needle thread S2031 located on the edge portions 2002 a, 2003 a side and a left needle thread S2032 located on the anti-edge portions 2002 a, 2003 a side.

[0166] The needle thread S2003 fixes the 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 first and second loops L2001, L2002 are continuous in the longitudinal direction via the needle thread S2003 at the ends L2011, L2021. The first back lock thread S2011 and the second back lock thread S2012 intersect with each other at the edge 2002a. The first loops L2001 and the second loops L2002 are continuous in the longitudinal direction at the edge 2002a.

[0167] FIG. 26 shows a sewing process in which the first fabric 2002 and the second fabric 2003 are sewn together by a plain stitch after the first end 2021 and the second end 2031 have been overlocked. For convenience of explanation, FIG. 26 shows the first end 2021 and the second end 2031 as being offset from each other, and also shows the overlock stitches (lock thread S2001) of the first end 2021 and the second end 2031 in a simplified manner. As shown in FIG. 26 , 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 with the edges 2002a, 2003a of the first fabric 2002 and the second fabric 2003 aligned. This forms the sewn portion 2004.

[0168] Fig. 27 is an enlarged schematic view showing the locking thread S2001 alone. As shown in Fig. 27, in this embodiment, the locking thread S2001 is made of threads including heat-fusible threads Sb and Sc.

[0169] The lock yarn S2001 is formed by spirally winding heat-fusible yarns Sb and Sc containing heat-fusible components around a base yarn Sa containing no heat-fusible components. In this embodiment, the base yarn Sa is formed, for example, of a polyester two-ply yarn or a three-ply twisted filament yarn (e.g., a filament yarn having a thickness of 75 dtex to 80 dtex, formed by three-ply twisting a filament yarn consisting of 24 single yarns). The heat-fusible yarns Sb and Sc may be polyamide-based fusible yarns, for example, a filament yarn having a thickness of 75 dtex to 80 dtex, formed by 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), with a length of 10,000 m and a weight of 1 g being called 1 dtex. The ratio of the heat-sealing yarns Sb and Sc to the weight of the lock yarn S2001 may be set to 25% or more and less than 50%, and is set to, for example, 39%.

[0170] The melting temperature of the thermal adhesive yarns Sb and Sc may be set to 100 degrees or more and 200 degrees or less, for example, 120 degrees or 130 degrees.

[0171] As shown in Figure 27, the fusion yarns Sb and 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. The twist directions of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc relative to the base yarn Sa are preferably opposite from the viewpoint of sewability. In this embodiment, 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 numbers of the lower heat fusion yarn Sb and the upper heat fusion yarn Sc may be set to 450 turns / m or more and 550 turns / m or less, and in this embodiment, the twist number is set to approximately 500 turns / m. The twist angle α of the lower heat fusion yarn Sb may be set to 10 degrees or more and 30 degrees or less, and in this embodiment, it is set to approximately 20 degrees. The twist angle β of the upper heat-fusion yarn may be set to between 10 degrees and 30 degrees, and in this embodiment is set to approximately 20 degrees. In this embodiment, each of the twist angles α and β is the angle between the axis X1 of the base yarn Sa and the lower heat-fusion yarn Sb or the upper heat-fusion yarn Sc.

[0172] 28 is an enlarged cross-sectional view schematically illustrating the area around the eye 2061 of the sewing needle 2006 that sews the first fabric 2002 and the second fabric 2003 together. As shown in FIG. 28 , the eye 2061 of the sewing needle 2006 is generally elliptical, having a major axis 2061 a and a minor axis 2061 b. The width d1 of the sewing needle 2006 is preferably small in order to reduce the diameter d of the needle eye in the first fabric 2002 and the second fabric 2003. On the other hand, the eye 2061 is preferably large relative to the width d1 of the sewing needle 2006. For example, a sewing machine needle size 14 manufactured by Organ Needle Co., Ltd. may be used, in which the width d1 of the sewing needle 2006 is 0.8 mm, and the eye 2061 has a major axis 2061 a length of approximately 0.8 mm and a minor axis 2061 b length of approximately 0.3 mm. In this embodiment, the width d1 of the sewing needle 2006 is the width of the portion of the sewing needle 2006 in the longitudinal direction where the minor shaft 2061b is located.

[0173] As shown in FIG. 28 , the diameter Z1 of the first lock thread S2001, indicated by the two-dot chain line, may be set to be 0.35 to 0.9 times the length Z of the major axis 2061a of the thread eye 2061 of the sewing needle 2006, for example, 0.5 times.

[0174] Figure 29 is a cross-sectional schematic diagram taken along line XXIX-XXIX in Figure 24, showing the sewn portion 2004 and the end bonded portion 2005. As shown in Figure 29, the end bonded portion 2005 is formed by stitching the first end portion 2021 and the second end portion 2031, which have been overcast, and then folding the second fabric 2003 back in the direction opposite to the direction in which the first fabric 2002 stretches, and then turning down the first end portion 2021 and the second end portion 2031 to one side and heat-sealing them to the back surface 2003b of the second fabric 2003 at a temperature of 100 to 200 degrees.

[0175] In the end bonding portion 2005, the heat-fusion yarns Sb and Sc of the locking thread S2001 are melted by heat and then cooled, bonding the first end portion 2021 and the second end portion 2031 to the main body portion 2030. The end bonding portion 2005 is distributed with adhesive 2091 remaining after the heat-fusion yarns Sb and Sc of the locking thread S2001 have melted. More specifically, as shown in Fig. 30 , the first end portion 2021 and the second end portion 2031 after the heat-fusion yarns Sb and Sc have been heat-melted are sewn together with the base yarn Sa of the locking thread S2001 and are also bonded together with the heat-fusion yarns Sb and Sc. In this embodiment, the end adhesive portion 2005 is a portion where the first end portion 2021 and the second end portion 2031 are adhered to the main body portion 2030 of the second fabric 2003 by adhesive 2091 distributed in the adhesive portion lock thread portion 2051 along the lock thread S2001.

[0176] 25 and 30 , for example, the end bonded portion 2005 is disposed between the edge portions 2002a, 2003a of the first fabric 2002 and the second fabric 2003 and the end portions L2011, L2021 of the first loop L2001 and the second loop L2002. The width of the end bonded portion 2005 roughly matches the width W2001 of the first loop L2001 to the second loop L2002. For example, when the ends are bonded with seam tape or the like, a base material is disposed in the end bonded portion on the opposite adhesive surface of the seam tape, but in this embodiment, no base material is disposed in the end bonded portion 2005.

[0177] FIG. 30 is an image of the bonded lock thread portion 2051 and its surrounding area taken with a scanning electron microscope (SEM) (Miniscope™3000, manufactured by Hitachi High-Technologies Corporation). The set magnification of the SEM image is 30x. As shown in FIG. 30 , in the end bonded portion 2005, the amount of the first adhesive 2091 distributed in the bonded lock thread portion 2051 along the lock thread S2001 (base thread Sa) is greater than the amount of the second adhesive 2092 distributed in the other portion R. In this embodiment, the bonded lock thread portion 2051 is a region including the portion 2051 where the lock thread S2001 is arranged and its vicinity 2052.

[0178] 31 , the amount of adhesive 2091 may be, for example, the thickness of adhesive 2091 laminated on the first fabric 2002 and the second fabric 2003. A thickness t1 of the adhesive 2091 distributed in the adhesive lock thread portion 2051 is thicker than a thickness t2 of the adhesive 2092 distributed in the other portion R.

[0179] In this embodiment, the bonded portion locking thread portion 2051 is sewn by a sewing machine. The sewing speed of the bonded portion locking 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 5000 rpm or more and 8000 rpm or less, and is set to, for example, 4000 rpm.

[0180] Next, a method for manufacturing the end fixing structure 2001 of two sewn together fabrics 2002 and 2003 will be described.

[0181] As shown in Fig. 25, a first fabric 2002 and a second fabric 2003 are prepared. The first fabric 2002 and the second fabric 2003 are overlapped with the front sides facing each other. A first end 2021, which is an end on one side in the width direction of the first fabric 2002, and a second end 2031, which is an end on one side in the width direction of the second fabric 2003, are overlocked with a locking thread S2001 including heat-sealing threads Sb and Sc.

[0182] As shown in Fig. 26 , the first end 2021 and the second end 2031 are stitched together with a sewing thread S2004 to form a seam 2004. As shown in Fig. 25 and 30 , the first end 2021 and the second end 2031 are laid down to one side and then bonded to the back surface 2003b of the main body 2030 of the second fabric 2003 to form an end bonding portion 2005, thereby obtaining an end fixing structure 2001 for the two sewn together fabrics 2002 and 2003. The heating method for applying heat to the first end 2021 and the second end 2031 can be, for example, a heat press that applies heat, pressure, and cooling, ultrasonic heating that vibrates the first end 2021 and the second end 2031 with ultrasonic vibrations and melts and bonds the thermal fusion threads Sb and Sc with the frictional heat generated between the ends by the vibration, or high-frequency heating that heats by potential movement at the molecular level using high-frequency energy (electromagnetic waves). An appropriate heating method, or a combination of multiple heating methods, may be adopted in consideration of the fabric thickness, the number of layers of fabric (the distance from the fabric surface to the fusion threads), and production efficiency.

[0183] With the above configuration, the end fixing structure 2001 according to this embodiment has the following advantages.

[0184] The end fixing structure 2001 has a first fabric 2002 having a first end 2021, a second fabric 2003 having a second end 2031, a lock thread S2001 that overlocks the first end 2021 and the second end 2031, a sewn portion 2004 where the first end 2021 and the second end 2031 are sewn together with a suture thread S2004, and an end bonding portion 2005 where the first end 2021 and the second end 2031 are folded down on one side or both sides and bonded to the main body portion 2020 of the first fabric 2002 and / or the main body portion 2030 of the second fabric 2003, and in the end bonding portion 2005, the amount of adhesive 2091 distributed in the bonded portion lock thread portion 2051 along the lock thread S2001 is greater than the amount of adhesive 2092 distributed in the other portion R.

[0185] According to the present invention, the first end 2021 and the second end 2031 can be fixed to the main body 2030 by the adhesive 2091 distributed in the adhesive lock thread portion 2051. The amount of adhesive 2092 distributed in the other portion R is reduced compared to the amount of adhesive 2091 distributed in the adhesive lock thread portion 2051, which prevents excessive adhesive distribution compared to when a tape material such as hot melt is applied to the entire end adhesive portion 2005. This prevents the fabric from hardening and increasing in weight, while providing an attractive fixation of the fabric ends. Because the first end 2021 and the second end 2031 are overlocked, a continuous end adhesive portion 2005 can be provided without interruption in the direction of extension of the lock thread S2001, thereby more effectively fixing the first end 2021 and the second end 2031 to the main body 2020, 2030.

[0186] 32(a), if the first end 2021 and the second end 2031 are overlocked and not bonded to the main body portion 2030 (no end bonding portion 2005 is provided), the seam allowance portion 2041 formed at the seam 2004 where the first end 2021 and the second end 2031 are sewn together will rise, and a depression will likely occur in the seam allowance portion 2041 on the front surface of the fabric, which will likely spoil the aesthetic appearance. In contrast, according to the present invention, as shown in FIG. 32(b), the first end 2021 and the second end 2031 have end bonding portions 2005 bonded to the main body portion 2030, which prevents the seam allowance portion 2041 from rising, making it less likely that a depression will occur in the seam allowance portion 2041 on the front surface of the fabric, making it easier to maintain a flat state and less likely to spoil the aesthetic appearance.

[0187] The first end 2021 and the second end 2031 are sewn together by an overlock stitch using a lock thread S2001. The lock thread S2001 has a first back lock thread S2011 located on the back surface 2002b side of the first end 2021 and a second back lock thread S2012 located on the back surface 2003b side of the second end 2031. The adhesive lock thread portion 2051 is at least the portion where the second back lock thread S2012 is located, tilted to one side and positioned opposite the main body portion 2030.

[0188] According to this configuration, the first end 2021 and the second end 2031 are integrally overlocked with the locking thread S2001, which simplifies the process for fixing the ends compared to when the first end 2021 and the second end 2031 are individually overlocked. By simply providing the adhesive locking thread portion 51 on the side of the first back locking thread S2011 or the second back locking thread S2012 that is tilted to one side and arranged facing the main body portions 2020, 2030, the first end 2021 and the second end 2031 can be fixed to the main body portions 2020, 2030, and the increase in adhesive can be suppressed compared to when an adhesive locking thread portion is also provided on the other side.

[0189] The manufacturing method of the end fixing structure 2001 includes preparing a first fabric 2002 having a first end 2021 and a second fabric 2003 having a second end 2031, overstitching the first end 2021 and the second end 2031 with a lock thread S2001 including heat-sealing threads Sb and Sc, and forming a seam 2004 by stitching the first end 2021 and the second end 2031 together, and then bending one or both of the first end 2021 and the second end 2031 and adhering them to the main body portions 2020, 2030 of the first fabric 2002 and / or the second fabric 2003 to form an end adhesive portion 2005.

[0190] According to the present invention, the first end 2021 and the second end 2031, which are overlocked with a locking thread S2001 including thermal adhesive threads Sb and Sc, can be fixed to the main body portions 2020 and 2030. This prevents excessive distribution of adhesive compared to when a tape member such as hot melt adhesive is placed over the entire end adhesive portion 2005. This prevents the fabric from hardening and increasing in weight, while allowing the fabric ends to be fixed in an attractive manner.

[0191] The first end 2021 and the second end 2031 are sewn together by an overlock stitch using a lock thread S2001. The lock thread S2001 has a first back lock thread S2011 located on the back surface 2002b side of the first end 2021 and a second back lock thread S2012 located on the back surface 2003b side of the second end 2031. At least the first back lock thread S2011 or the second back lock thread S2012, which is tilted to one side and arranged opposite the main body portions 2020, 2030, has heat-bonding threads Sb, Sc.

[0192] According to this configuration, the first end 2021 and the second end 2031 are integrally overlocked with the locking thread S2001, which simplifies the process for fixing the ends compared to when the first end 2021 and the second end 2031 are overlocked separately. At least one of the first back locking thread S2011 or the second back locking thread S2012, which is tilted to one side and arranged opposite the main body portions 2020, 2030, contains the heat-sealing threads Sb, Sc, which allows the first end 2021 and the second end 2031 to be fixed to the main body portions 2020, 2030. Compared to when the other also contains the heat-sealing threads Sb, Sc, an increase in adhesive can be suppressed.

[0193] 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.

[0194] This configuration allows the overlock pitch P2001 to be appropriately set. If the pitch P2001 is less than 0.5 mm, it is difficult to move the sewing needle using a sewing machine, etc., while if the pitch P2001 exceeds 3.0 mm, discontinuities in the molten adhesive 2091 distributed in the lock thread portion 2051 of the adhesive portion along the lock thread S2001 are likely to occur, making it difficult to prevent the first end portion 2021 and the second end portion from peeling off from the main body portions 2020 and 2030.

[0195] The lock yarn S2001 is formed by spirally winding heat-fusible yarns Sb and Sc containing a heat-fusible component around a base yarn Sa containing no heat-fusible component.

[0196] According to this configuration, even when the heat-sealed threads Sb and Sc are melted after heat welding, the base thread Sa remains in the adhesive lock thread portion, so that fraying of the ends due to deterioration over time, which occurs when the adhesive lock thread portion 2051 is locked with an adhesive or the like, can be suppressed.

[0197] The ratio of the heat-fusible yarns Sb and Sc to the weight of the lock yarn S2001 is 25% or more and 50% or less.

[0198] This configuration allows the proportions of the heat-fusion yarns Sb and Sc contained in the lock thread S2001 to be appropriately set. If the proportions of the heat-fusion yarns Sb and Sc contained in the lock thread S2001 are less than 25%, the amount of molten adhesive 2091 distributed in the bonded lock thread portion 2051 along the lock thread S2001 is likely to be insufficient, resulting in insufficient adhesive strength or adhesive area, and making it likely that the first end portion 2021 and the second end portion 2031 will peel off from the main body portions 2020 and 2030.

[0199] If the ratio of the heat-sealing yarns Sb and Sc contained in the lock yarn S2001 exceeds 50%, the thickness of the base yarn Sa will become thinner and the seam strength will likely be weakened if the thickness of the lock yarn S2001 is kept constant.

[0200] The melting temperature of the thermal adhesive yarns Sb and Sc is 100 degrees or more and 200 degrees or less.

[0201] According to this configuration, the melting temperature of the thermal adhesive threads Sb and Sc can be appropriately set. If the melting temperature is less than 100°C, the thermal adhesive threads Sb and Sc may melt due to the temperature of the sewing needle 2006, which is increased by frictional heat between the sewing needle 2006 and the fabric during sewing. Furthermore, the thermal adhesive threads Sb and Sc may melt when ironed or tumble dried after use, resulting in a decrease in 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.

[0202] The ratio of the diameter Z1 of the lock thread S2001 to the length Z of the major axis 2061a of the thread eye 2061 of the sewing needle 2006 through which the lock thread S2001 is inserted is 0.35 to 0.9.

[0203] This configuration allows 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 to 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 is insufficient, making it difficult to achieve the desired sewing strength. If the ratio of the diameter Z1 of the lock thread S2001 exceeds 0.9, the temperature of the sewing needle 2006 increases 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.

[0204] 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 be between 3000 rpm and 8000 rpm.

[0205] This configuration allows the sewing speed to be set appropriately. If the sewing speed is less than 3,000 rpm, production efficiency decreases. If the sewing speed exceeds 8,000 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 rise of the sewing needle 2006 may melt the thermal adhesive threads Sb and Sc.

[0206] In the present embodiment, the first back lock yarn S2011 and the second back lock yarn S2012 include the heat-sealed yarns Sb and Sc, but the present invention is not limited to this. For example, the second back lock yarn S2012, which is disposed opposite the back surface 3b of the main body 2030 of the second fabric 2003 to be laid down, may include the heat-sealed yarns Sb and Sc, and the first back lock yarn S2011 may be composed of a so-called regular yarn such as a spun yarn or a filament yarn that does not include the heat-sealed yarns Sb and Sc. A spun yarn is a spun yarn made by processing staple fibers.

[0207] In this embodiment, the end adhesive portion 2005 is described as being formed by inclining the first end portion 2021 and the second end portion 2031 to one side and heat-sealing them to the back surface 2003b of the second fabric 2003, but this is not limited to this, and the end adhesive portion 2005 may also be formed by inclining the first end portion 2021 and the second end portion 2031 to one side and heat-sealing them to the back surface 2002b of the first fabric 2002.

[0208] In this embodiment, the first end 2021 and the second end 2031 are overcast using a single-needle, three-thread lockstitch machine, but the present invention is not limited to this and the first end 2021 and the second end 2031 may be overcast using a two-needle, four-thread lockstitch machine. In this case, since two needle threads S2003 are arranged along the direction in which the end of the fabric extends and fix the loop to the fabric, one of the two needle threads may be used to substitute for the base stitch of the suture thread S2004, as shown by the two-dot chain line in Fig. 29 .

[0209] In this embodiment, a configuration has been described in which the 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 to form the stitching portion 2004, but this is not limited to this, and the stitching portion 2004 (suture thread S2004) may not be provided.

[0210] In this embodiment, the first end 2021 and the second end 2031 are configured to be overlocked together, but this is not limited to this. For example, as shown in Figure 33, the first end 2121 and the second end 2131 may be overlocked with lock threads S2005 and S2006, respectively, and may also be folded down on both sides.

[0211] More specifically, the fabric 2102 may have a first end 2121 of the first fabric 2102 overlocked with a first locking thread S2005, a second end 2131 of the second fabric 2103 overlocked with a second locking thread S2006, a sewn portion 2104 where the first end 2121 and the second end 2131 are sewn together with a suture thread S2007, and end bonding portions 2105, 2105 where the folded first end 2121 and the second end 2131 are bonded to the main body portion 2120 of the first fabric 2002 and the main body portion 2130 of the second fabric 2003, respectively.

[0212] 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.

[0213] 30 and 31 , the amount of adhesive 2091 distributed in the bonded 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 bonded 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 and 2130, are arranged.

[0214] The configuration of the end fixing structure 200101 shown in Figure 33 has the following effects.

[0215] 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 is located on the back surface 2103b side of the second end 2131. The end adhesive portion 2105 has a first end 2121 and a second end 2131 which are both folded down and adhered to the main body portions 2120 and 2130, respectively, and the adhesive portion lock thread portion 2051 is a portion where 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 are arranged.

[0216] According to this configuration, the first end portion 2121 and the second end portion 2131 can be bonded to the main body portions 2120 and 2130, respectively, by the adhesive 2091 distributed in the bonded lock thread portion 2051.

[0217] 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. and a second back side thread S2061 located on the surface 2103c side, and a second front side thread S2062 located on the surface 2103c side, and the end bonding portion 2105 has a first end 2121 and a second end 2131 both folded down and bonded to the main body portions 2120, 2130, respectively, and at least the first back side thread S2051 and the second back side thread S2061 arranged opposite the main body portions 2120, 2130 have heat-sealed threads Sb, Sc.

[0218] According to this configuration, the first end portion 2121 and the second end portion 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, out of the first locking threads S2005 and the second locking threads S2006 of the laid-down first end portion 2121 and the second end portion 2131. Compared to the case where the first front side thread S2052 and the second front side thread S2062 also contain the heat-sealing threads Sb, Sc, an increase in adhesive can be suppressed.

[0219] The end fixing structure 2001 of the present invention may be applied to sewing together two or more pieces of fabric used in clothing, hats, bags, gloves, tents, tarps, sleeping bags, sheets, umbrellas, etc.

[0220] The edge fixing structure 2001 of the present invention can replace the seam allowance of clothing where overlock is used. Specifically, when used in areas 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, chafing against the wearer can be suppressed and the feeling of contact can be easily eliminated.

[0221] The 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.

[0222] [Note] The present disclosure includes the following aspects.

[0223] [Aspect 1] A heat-fusible sewing thread comprising: a base yarn; a first heat-fusible yarn containing a heat-fusible component and twisted with the base yarn in either an S-twist or a Z-twist; and a second heat-fusible yarn containing a heat-fusible component and twisted with the base yarn in a direction different from the one direction on the outer periphery of the first heat-fusible yarn.

[0224] [Aspect 2] The heat-bondable sewing thread according to Aspect 1, wherein the one direction is an S twist and the other direction is a Z twist.

[0225] [Aspect 3] The heat-fusible sewing thread according to Aspect 1 or 2, wherein the ratio of the first heat-fusible yarn and the second heat-fusible yarn to the weight of the sewing thread is 25% or more and 50% or less.

[0226] [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.

[0227] [Aspect 5] The heat-fusible sewing thread according to any one of Aspects 1 to 4, wherein the number of twists of the first and second heat-fusible yarns is 450 turns / m or more and 550 turns / m or less.

[0228] [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.

[0229] [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.

[0230] [Aspect 8] A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in Aspect 1, comprising: overlocking a first end of a first waterproof fabric with a first locking thread including the heat-fusible sewing thread; overlocking a second end of a second waterproof fabric with a second locking thread including the heat-fusible sewing thread; sewing the first and second fabrics together with a suture thread including the heat-fusible sewing thread while the first and second end ends are overlapped to form a seam; heat-welding the first and second end ends to form an end adhesion portion; and melting the suture thread in the seam to close the needle hole.

[0231] Aspect 9 is a manufacturing method for a waterproof joint structure according to Aspect 8, wherein the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other; the first locking thread has a first one-side thread located on the first opposing surface and a first other-side thread located on a first opposite surface opposite the first opposing surface; the second locking thread has a second one-side thread located on the second opposing surface and a second other-side thread located on a second opposite surface opposite the second opposing surface; and the first one-side thread and the second one-side thread include the heat-fusible sewing thread.

[0232] [Aspect 10] A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in Aspect 1, comprising: preparing a first fabric having a first end and a second fabric having a second end; arranging an adhesive member between the first end and the second end; overlocking the first end and the second end with a first locking thread while the first end and the second end are overlapped; sewing the first fabric and the second fabric with a suture including the heat-fusible sewing thread while the first end and the second end are overlapped to form a seam; melting the adhesive member to heat-seal the first end and the second end to form an end bonded portion; and melting the suture in the seam to close the needle hole.

[0233] [Aspect 11] A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in Aspect 1, comprising: preparing a first fabric having a first end and a second fabric having a second end; ultrasonically welding the first end and the second end in an overlapping state to form an end joint; sewing the first end and the second end together with a suture thread including the heat-fusible sewing thread to form a seam; and melting the suture thread in the seam to seal the needle hole.

[0234] [Aspect 12] A waterproof joint structure manufactured by the manufacturing method described in Aspect 8, comprising: a first fabric having a first end; a second fabric having a second end; an end bonded portion where the first end and the second end are bonded; and a stitched portion where 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.

[0235] [Aspect 13] The waterproof joint structure according to aspect 12, wherein the seam is formed by a plain seam.

[0236] [Aspect 14] The waterproof joint structure according to aspect 12 or aspect 13, wherein the end adhesive portion is an adhesive portion bonded by an adhesive member disposed between the first end portion and the second end portion.

[0237] [Aspect 15] A waterproof joint structure according to Aspect 12 or Aspect 13, wherein the first end and the second end are overlocked with a first locking thread and a second locking thread, respectively; the end adhesive portion is a portion where the first end and the second end are adhered by adhesive distributed in the adhesive portion locking thread portion along the first and second locking threads; and the amount of adhesive distributed in the adhesive portion locking thread portion at the end adhesive portion is greater than the amount of adhesive distributed in other portions.

[0238] Aspect 16 is a waterproof joint structure according to Aspect 15, wherein the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other, the first locking thread has a first one-side thread located on the first opposing surface and a first other-side thread located on a first opposite-side surface opposite the first opposing surface, the second locking thread has a second one-side thread located on the second opposing surface and a second other-side thread located on a second opposite-side surface opposite the second opposing surface, and the adhesive locking thread portion is a portion where at least the first one-side thread and the second one-side thread are arranged.

[0239] [Aspect 17] The waterproof joint structure according to Aspect 12 or Aspect 13, wherein the end bonding portion is an ultrasonic fusion portion in which the first end portion and the second end portion are joined by melting the first fabric and the second fabric without using an adhesive.

[0240] Aspect 18 is a method for manufacturing an end fixing structure using the heat-fusible sewing thread described in Aspect 1, comprising the steps of: preparing a first fabric having a first end and a second fabric having a second end; overlocking the first end and the second end with a locking thread including the heat-fusible sewing thread; and bending the first end and the second end on one side or both sides, and melting the heat-fusible sewing thread to bond it to a main body portion of the first fabric and / or the second fabric, thereby forming an end bonding portion.

[0241] Aspect 19 is a manufacturing method of an end fixing structure according to Aspect 18, in which the first end and the second end are sewn together by an overlock stitch with the locking thread, the locking thread having a first back locking thread located on the back surface side of the first end and a second back locking thread located on the back surface side of the second end, and at least the first back locking thread or the second back locking thread arranged facing the main body portion in a one-sided position has the heat-fusible sewing thread.

[0242] Aspect 20 is a manufacturing method of an end fixing structure according to Aspect 18, wherein the locking yarn includes a first locking yarn for overseaming the first end and a second locking yarn for overseaming the second end, the first locking yarn includes a first back side yarn located on the back side of the first end and a first front side yarn located on the front side, the second locking yarn includes a second back side yarn located on the back side of the second end and a second front side yarn located on the front side, the end bonding portion has both the first end and the second end bent down and bonded to the main body portion, and at least the first back side yarn and the second back side yarn arranged opposite the main body portion include the heat-fusible sewing thread.

[0243] [Aspect 21] A waterproof joined structure manufactured by the manufacturing method described in Aspect 18, comprising: a first fabric having a first end; a second fabric having a second end; a locking thread that overlocks the first end and the second end; and an end adhesive portion where the first end and the second end are overlocked on one side or both sides and adhered to a main body portion of the first fabric and / or the second fabric, wherein the amount of adhesive distributed in the locking thread portion of the adhesive portion along the locking thread is greater than the amount of adhesive distributed in other portions of the end fixing structure.

[0244] Aspect 22: The end fixing structure according to Aspect 21, wherein the first end and the second end are sewn together by an overlock stitch with the locking thread, the locking thread has a first back locking thread located on the back side of the first end and a second back locking thread located on the back side of the second end, and the adhesive section locking thread portion is at least a portion where the first back locking thread or the second back locking thread is disposed, tilted to one side and facing the main body portion.

[0245] Aspect 23: The end fixing structure according to Aspect 21, wherein the locking thread comprises a first locking thread for overlocking the first end and a second locking thread for overlocking the second end; the first locking thread comprises a first back side thread located on the back side of the first end and a first front side thread located on the front side; the second locking thread comprises a second back side thread located on the back side of the second end and a second front side thread located on the front side; the end bonding portion comprises the first end and the second end folded down and bonded to the main body, respectively; and the bonded portion locking thread portion is at least a portion where the first back side thread and the second back side thread arranged opposite the main body are arranged.

[0246] 6 Sewing needle 61 Thread hole S1 Heat-sealable sewing thread Sa Base thread Sb Lower heat-sealable thread (first heat-sealable thread) Sc Upper heat-sealable thread (second heat-sealable thread)

Claims

1. A heat-fusible sewing thread comprising: a base yarn; a first heat-fusible thread containing a heat-fusible component and twisted with the base yarn in either an S-twist or a Z-twist; and a second heat-fusible thread containing a heat-fusible component and twisted with the base yarn in a direction different from the one twist on the outer periphery of the first heat-fusible thread.

2. The heat-bondable sewing thread according to claim 1, wherein the one direction is an S twist and the other direction is a Z twist.

3. The heat-fusible sewing thread according to claim 1 or 2, wherein the ratio of the first heat-fusible thread and the second heat-fusible thread to the weight of the sewing thread is 25% or more and 50% or less.

4. The heat-sealable sewing thread according to claim 1 or 2, wherein the melting temperatures of the first and second heat-sealable threads are between 100°C and 200°C.

5. The heat-fusible sewing thread according to claim 1 or 2, wherein the number of twists of the first and second heat-fusible threads is 450 turns / m or more and 550 turns / m or less.

6. The heat-bondable sewing thread according to claim 1 or 2, wherein the ratio of the diameter of the sewing thread to the length of the major axis of the eye of the sewing needle through which the sewing thread is inserted is 0.35 to 0.

9.

7. A heat-sealable sewing thread, wherein the first and second heat-sealable threads are polyamide-based heat-sealable threads.

8. A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in claim 1, comprising: overlocking a first end of a first waterproof fabric with a first locking thread including the heat-fusible sewing thread; overlocking a second end of a second waterproof fabric with a second locking thread including the heat-fusible sewing thread; forming a seam by sewing the first fabric and the second fabric with a suture thread including the heat-fusible sewing thread while the first end and the second end are overlapped; heat-welding the first end and the second end to form an end adhesion portion; and melting the suture thread in the seam to close the needle hole.

9. A method for manufacturing a waterproof joint structure as described in claim 8, wherein the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other, the first locking thread has a first one-side thread located on the first opposing surface and a first other-side thread located on a first opposite surface opposite the first opposing surface, the second locking thread has a second one-side thread located on the second opposing surface and a second other-side thread located on a second opposite surface opposite the second opposing surface, and the first one-side thread and the second one-side thread include the heat-fusible sewing thread.

10. A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in claim 1, comprising the steps of: preparing a first fabric having a first end and a second fabric having a second end; arranging an adhesive member between the first end and the second end; overlaying the first end and the second end with a first locking thread; sewing the first fabric and the second fabric with a suture thread including the heat-fusible sewing thread with the first end and the second end overlapped to form a seam; melting the adhesive member to heat-seal the first end and the second end to form an end bonded portion; and melting the suture thread in the seam to close the needle hole.

11. A method for manufacturing a waterproof joint structure using the heat-fusible sewing thread described in claim 1, comprising: preparing a first fabric having a first end and a second fabric having a second end; ultrasonically welding the first end and the second end in an overlapping state to form an end joint; sewing the first end and the second end together with a suture thread including the heat-fusible sewing thread to form a seam; and melting the suture thread in the seam to close the needle hole.

12. A waterproof joint structure manufactured by the manufacturing method described in claim 8, comprising: a first fabric having a first end; a second fabric having a second end; an end-bonded portion where the first end and the second end are bonded; and a stitched portion where the first end and the second end are sewn together with a suture thread and the needle hole of the suture thread is closed with an adhesive.

13. The waterproof joint structure according to claim 12, wherein the seams are constructed by plain stitching.

14. A waterproof joint structure as described in claim 12 or claim 13, wherein the end adhesive portion is an adhesive portion bonded by an adhesive member arranged between the first end and the second end.

15. A waterproof joint structure as described in claim 12 or claim 13, wherein the first end and the second end are overlocked with a first locking thread and a second locking thread, respectively, and the end adhesive portion is a portion where the first end and the second end are adhered by adhesive distributed in the adhesive portion locking thread portion along the first and second locking threads, and the amount of adhesive distributed in the adhesive portion locking thread portion at the end adhesive portion is greater than the amount of adhesive distributed in other portions.

16. The waterproof joint structure according to claim 15, wherein the first fabric and the second fabric each have a first opposing surface and a second opposing surface that face each other, the first locking thread has a first one-side thread located on the first opposing surface and a first other-side thread located on a first opposite-side surface opposite the first opposing surface, the second locking thread has a second one-side thread located on the second opposing surface and a second other-side thread located on a second opposite-side surface opposite the second opposing surface, and the adhesive locking thread portion is at least the portion where the first one-side thread and the second one-side thread are arranged.

17. A waterproof joint structure as described in claim 12 or claim 13, wherein the end bonding portion is an ultrasonic fusion portion in which the first end and the second end are joined by melting the first fabric and the second fabric without the use of adhesive.

18. A method for manufacturing an end fixing structure using the heat-fusible sewing thread described in claim 1, comprising the steps of: preparing a first fabric having a first end and a second fabric having a second end; overlocking the first end and the second end with a locking thread containing the heat-fusible sewing thread; and bending the first end and the second end on one side or both sides, melting the heat-fusible sewing thread and bonding it to the main body of the first fabric and / or the second fabric, thereby forming an end bonding portion.

19. A method for manufacturing an end fixing structure as described in claim 18, wherein the first end and the second end are sewn together with the locking thread by overlocking, the locking thread comprises a first back locking thread located on the back side of the first end and a second back locking thread located on the back side of the second end, and at least the first back locking thread or the second back locking thread, which is turned to one side and arranged facing the main body, comprises the heat-fusible sewing thread.

20. A method for manufacturing an end fixing structure as described in claim 18, wherein the locking thread comprises a first locking thread for overseaming the first end and a second locking thread for overseaming the second end, the first locking thread comprises a first back side thread located on the back side of the first end and a first front side thread located on the front side, the second locking thread comprises a second back side thread located on the back side of the second end and a second front side thread located on the front side, the end bonding portion has the first end and the second end both folded down and bonded to the main body portion, and at least the first back side thread and the second back side thread arranged opposite the main body portion comprise the heat-fusible sewing thread.

21. A waterproof joint structure manufactured by the manufacturing method described in claim 18, comprising: a first fabric having a first end; a second fabric having a second end; a locking thread that overlocks the first end and the second end; and an end adhesive portion where the first end and the second end are overlocked on one side or both sides and adhered to the main body portion of the first fabric and / or the second fabric, wherein the amount of adhesive distributed in the locking thread portion of the adhesive portion along the locking thread is greater than the amount of adhesive distributed in other portions of the end adhesive portion.

22. The end fixing structure according to claim 21, wherein the first end and the second end are sewn together with the locking thread by an overlock stitch, the locking thread comprises a first back locking thread located on the back side of the first end and a second back locking thread located on the back side of the second end, and the adhesive locking thread portion is at least a portion where the first back locking thread or the second back locking thread is arranged, tilted to one side and facing the main body portion.

23. The end fixing structure according to claim 21, wherein the locking thread comprises a first locking thread for overlocking the first end and a second locking thread for overlocking the second end, the first locking thread comprising a first back side thread located on the back side of the first end and a first front side thread located on the front side, the second locking thread comprising a second back side thread located on the back side of the second end and a second front side thread located on the front side, the end adhesive portion comprises the first end and the second end both folded down and adhesively bonded to the main body, and the adhesive portion locking thread portion is at least the portion where the first back side thread and the second back side thread arranged opposite the main body are arranged.

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