Fiber product

Abstract

A fiber product includes a tungsten wire (10) having an elongation of 5% or more, and an organic fiber (20) combined with the tungsten wire (10).

Description

Technical Field

[0001] This invention relates to fiber products. Background Technology

[0002] Patent document 1 discloses a metal fiber that is made by combining tungsten wire with roughened surface with aromatic polyamide fiber or nylon fiber.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2018-080413 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] Tungsten wire generally has low ductility. Therefore, tungsten wire may break if it cannot keep up with the expansion and contraction of the fiber.

[0008] Therefore, the object of the present invention is to provide a fiber product capable of suppressing the breakage of tungsten wires.

[0009] Methods for solving problems

[0010] One aspect of the present invention comprises: tungsten wire with an elongation of 5% or more; and organic fiber combined with the tungsten wire.

[0011] Invention Effects

[0012] The fiber product according to the present invention can suppress the occurrence of tungsten wire breakage. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the yarn twisting method in the implementation embodiment.

[0014] Figure 2 This is a flowchart illustrating a method for manufacturing tungsten wires in the twisted yarn of the embodiment.

[0015] Figure 3 This is a scatter plot showing the relationship between the elongation and tensile strength of the tungsten wires in the examples and comparative examples.

[0016] Figure 4 This is a schematic diagram showing the state of the twisted yarn before and after elongation in the embodiment.

[0017] Figure 5 It is a graph showing the maximum elongation of each type of fiber that can be used as an organic fiber.

[0018] Figure 6This is a diagram illustrating an example of the Lp / Rp ratio of twisted yarn when various organic fibers of different diameters are wound with tungsten wire in a specified number of rolls.

[0019] Figure 7 This is a graph showing the required elongation Tw for tungsten wire within the range of 0% to 40% elongation Tp of organic fibers.

[0020] Figure 8 This is a graph showing the required elongation Tw for tungsten wire within the range of 0% to 100% elongation Tp of organic fibers.

[0021] Figure 9 This is a schematic diagram of a twisted fiber product having an embodiment.

[0022] Figure 10 This is a diagram showing a summary of the tungsten wire winding test of the embodiment.

[0023] Figure 11 This is a cross-sectional view of a metal mesh woven using tungsten wire and organic fibers as described in the embodiment.

[0024] Figure 12A This is a diagram showing the appearance of the tungsten wire of Example 16 after the winding test.

[0025] Figure 12B It is Figure 12A The image is obtained by magnifying a portion of it.

[0026] Figure 13A This is a diagram showing the appearance of the tungsten wire of Comparative Example 10 after the winding test.

[0027] Figure 13B It is Figure 13A The image is obtained by magnifying a portion of it. Detailed Implementation

[0028] The fiber articles according to embodiments of the present invention will now be described in detail using the accompanying drawings. It should be noted that the embodiments described below are specific examples of the present invention. Therefore, the numerical values, shapes, materials, constituent elements, arrangements and connection methods of constituent elements, steps, and order of steps shown in the following embodiments are merely examples and are not intended to limit the present invention. Consequently, constituent elements not described in the independent claims among the constituent elements in the following embodiments will be described as optional constituent elements.

[0029] Furthermore, these figures are schematic diagrams and may not be perfectly accurate. Therefore, for example, the scales may not be consistent across different figures. Additionally, in each figure, substantially identical components are labeled with the same symbol, and repetitive descriptions are omitted or simplified.

[0030] Furthermore, in this specification, terms indicating relationships between elements, terms indicating the shape of elements, and numerical ranges are not merely expressions with a strict meaning, but also imply expressions that include substantially equivalent ranges, such as differences of approximately a few percent.

[0031] (Implementation Method)

[0032] [Twisting yarn]

[0033] First, regarding the structure of the twisted yarn in this embodiment, using Figure 1 Please provide an explanation. Figure 1 This is a schematic diagram illustrating the twisted yarn 1 of this embodiment.

[0034] Twisted yarn 1 is an example of a fiber product. For example... Figure 1 As shown, the twisted yarn 1 comprises: tungsten wire 10; and organic fiber 20 combined with tungsten wire 10. Tungsten wire 10 and organic fiber 20 constitute twisted yarn 1.

[0035] In this embodiment, the twisted yarn 1 is a core-spun yarn with organic fiber 20 as the core yarn and tungsten wire 10 as the sheath yarn. For example, the twisted yarn 1 is manufactured by stretching and fixing the organic fiber 20 as the core yarn, and then winding the organic fiber 20 around the tungsten wire 10 as the sheath yarn (i.e., performing a covering process).

[0036] Tungsten wire 10 is wound along the outer surface of organic fiber 20 at a predetermined interval. For example... Figure 1 As shown, the tungsten wire 10 has gaps in each roll, but adjacent rolls can also be tightly packed together.

[0037] The specific structure and manufacturing method of the tungsten wire 10 will be explained below.

[0038] Organic fiber 20 is at least one fiber selected from synthetic fibers, natural fibers, and regenerated fibers. Organic fiber 20 may be, for example, a synthetic fiber, such as an aromatic polyamide fiber or a nylon-based fiber. As an aromatic polyamide fiber, for example, a fiber manufactured using an aromatic polyamide resin material such as Kevlar (registered trademark) can be used. As a nylon-based fiber, for example, a fiber manufactured using ultra-high molecular weight polyethylene such as Dyneema (registered trademark) can be used.

[0039] It should be noted that the chemical fibers used as organic fiber 20 are not limited to those mentioned above; other materials such as polyethylene, polyester, polypropylene, polyurethane, polyvinyl chloride, and acrylic acid can also be used. Alternatively, organic fiber 20 can also be a semi-synthetic fiber or a regenerated fiber. Furthermore, organic fiber 20 can also be a natural fiber such as plant or animal fibers. For example, cotton, wool, silk, hemp, and rayon can be used as organic fiber 20.

[0040] exist Figure 1 In the example shown, the organic fiber 20 is a monofilament, but it is not limited to this. The organic fiber 20 can also be a multifilament, that is, an aggregate of multiple monofilaments. When the organic fiber 20 is a monofilament, the elongation of the organic fiber 20 is, for example, 70% or less.

[0041] It should be noted that the elongation refers to the total elongation at break, measured using an elongation meter. Specifically, the elongation of organic fiber 20 is the total elongation at break, which is the value obtained by summing the elastic elongation and plastic elongation measured by the elongation meter, expressed as a percentage relative to the distance from the meter's markings. Simply put, elongation represents the ratio of the difference between the length after elongation and the length before elongation to the length before elongation. A positive elongation value means the wire has elongated, while a negative elongation value means the wire has contracted. The same applies to the elongation of tungsten wire 10.

[0042] In this embodiment, the diameter of the organic fiber 20 is larger than that of the tungsten wire 10, for example, by 100 μm or more, but it is not limited thereto. It should be noted that the diameter of the organic fiber 20 can be equal to or smaller than that of the tungsten wire 10.

[0043] When the organic fiber 20 is a monofilament, the diameter of the organic fiber 20 is expressed as the maximum width of the cross-section (orthogonal to the axial direction) of a single filament. When the organic fiber 20 is a multifilament, the diameter of the organic fiber 20 is expressed as the maximum width of the cross-section of the multifilament, that is, the maximum width of the cross-section (orthogonal to the axial direction) of the aggregate of multiple monofilaments.

[0044] It should be noted that the twisted yarn 1 can also be a twisted yarn formed by twisting tungsten wire 10 and organic fiber 20 together. For example, twisted yarn is manufactured by twisting tungsten wire 10 and organic fiber 20 side by side (i.e., performing a twisting process). At least one of tungsten wire 10 and organic fiber 20 can also be multifilament.

[0045] [Tungsten wire]

[0046] Next, the structure of the tungsten wire 10 will be explained.

[0047] Tungsten wire 10 is an alloy wire made of tungsten (W) and at least one metallic element other than tungsten (hereinafter referred to as alloying element). The tungsten content in tungsten wire 10 is, for example, 90% by mass or more. Here, content refers to the ratio of the mass of the metallic element (e.g., tungsten) to the mass of tungsten wire 10. The tungsten content can be 95% by mass or more, 99% by mass or more, or 99.9% by mass or more.

[0048] At least one alloying element is a metallic element contained in Group 7 or Group 8 of the periodic table. Specifically, the alloying element is rhenium (Re) from Group 7 or ruthenium (Ru) from Group 8. For example, tungsten wire 10 is an alloy wire of tungsten and rhenium (hereinafter referred to as rhenium-tungsten alloy wire). Alternatively, tungsten wire 10 is an alloy wire of tungsten and ruthenium (hereinafter referred to as ruthenium-tungsten alloy wire). It should be noted that tungsten wire 10 can also be an alloy wire of tungsten with two or more alloying elements, as is the case with alloy wires of tungsten, rhenium, and ruthenium.

[0049] In the case of rhenium-tungsten alloy wire, the rhenium content is, for example, 0.1% to 10% by mass. The rhenium content can also be 0.5% to 9% by mass, or 3% to 5% by mass. In the case of ruthenium-tungsten alloy wire, the ruthenium content is, for example, 0.05% to 0.3% by mass. The ruthenium content can also be 0.1% to 0.2% by mass.

[0050] The higher the rhenium and / or ruthenium content, the higher the elongation and tensile strength of the tungsten wire 10. However, if the tensile strength increases, it becomes difficult to increase the elongation. Furthermore, the higher the rhenium and / or ruthenium content, the more difficult it is to reduce the diameter of the tungsten wire 10. In this embodiment, based on the in-depth research of the inventors of this application, by focusing on the content of alloying elements and the thinning process, a thin tungsten wire 10 with high elongation and high tensile strength has been achieved. The specific manufacturing method of the tungsten wire 10 will be described below.

[0051] The diameter of the tungsten wire 10 is, for example, 40 μm or less. The diameter of the tungsten wire 10 can be 30 μm or less, or 20 μm or less. For example, the diameter of the tungsten wire 10 can be 18 μm or less, or 15 μm or less, or 12 μm or less, or 10 μm or less. The diameter of the tungsten wire 10 can also be as small as the processing limit (e.g., 5 μm).

[0052] In this embodiment, the elongation of the tungsten wire 10 is 5% or more. Therefore, during the manufacture and use of the twisted yarn 1 incorporating the tungsten wire 10, breakage of the tungsten wire 10 can be suppressed. The elongation of the tungsten wire 10 can be 7% or more, 9% or more, 11% or more, 13% or more, or 16% or more. The higher the elongation, the better the effect of suppressing breakage of the tungsten wire 10.

[0053] The tensile strength of tungsten wire 10 is, for example, 1600 MPa (= N / mm²). 2The tensile strength is approximately 2400 MPa. Therefore, during the manufacture and use of the twisted yarn 1 incorporating the tungsten wire 10, breakage of the tungsten wire 10 can be suppressed. The tensile strength of the tungsten wire 10 can be 1700 MPa or higher, 1800 MPa or higher, 2000 MPa or higher, or 2100 MPa or higher. The higher the tensile strength, the better the effect of suppressing breakage of the tungsten wire 10.

[0054] [Manufacturing Method]

[0055] Next, regarding the manufacturing method of the tungsten wire 10 in this embodiment, using... Figure 2 Please provide an explanation. Figure 2 This is a flowchart illustrating an example of a method for manufacturing the tungsten wire 10 according to this embodiment.

[0056] like Figure 2 As shown, firstly, a metal ingot is prepared (S10). Specifically, firstly, a mixture is prepared by mixing tungsten powder with powder formed from an alloy metal (e.g., rhenium powder or ruthenium powder) in a specified ratio. The average particle size of the powder is, for example, in the range of 3 μm to 4 μm, but is not limited thereto. By pressing and sintering the prepared mixture, a tungsten alloy ingot is produced. The ingot is, for example, a rod-shaped ingot with a cross-sectional diameter of about 15 mm.

[0057] Next, the ingot is subjected to die forging (S11). Specifically, the ingot is stretched by forging and compressing it from all sides, thereby forming a wire-shaped tungsten wire. Instead of die forging, rolling can also be used. Die forging (S11) is repeated together with annealing (S13).

[0058] Specifically, through repeated die forging, the diameter of the ingot decreases in the order of 13.6 mm, 10.6 mm, 8 mm, 6.5 mm, and 3.3 mm. When the ingot diameter reaches these values ​​("Yes" in S12), annealing is performed (S13). The annealing temperature is, for example, 2400°C. After the diameter becomes 3.3 mm, annealing and die forging are performed again to bring the diameter to 3 mm.

[0059] Next, the 3mm diameter tungsten wire, after being forged, is heated at 900°C (S14). Specifically, the tungsten wire is heated directly using a burner or similar device. By heating the tungsten wire, an oxide layer is formed on its surface to prevent breakage during subsequent heating and drawing processes.

[0060] Next, heated wire drawing (S15) is performed. Specifically, tungsten wire is drawn while heated using one or more drawing dies; that is, tungsten wire drawing (reduction in diameter) is performed. The heating temperature is, for example, 1000°C. It should be noted that the higher the heating temperature, the better the machinability of the tungsten wire, and therefore the easier it is to draw. The heated wire drawing is performed repeatedly while changing the drawing die. The reduction in cross-sectional area of ​​the tungsten wire produced by one drawing using one drawing die is, for example, 10% to 40%. In the heated wire drawing process, a lubricant obtained by dispersing graphite in water can also be used.

[0061] Next, the drawn tungsten wire undergoes an intermediate recrystallization treatment (S16). Specifically, the tungsten wire is heated to a temperature of 1200°C or higher, causing the crystals contained in the tungsten wire to recrystallize. The heating and drawing process and the intermediate recrystallization treatment are repeated until the drawing process is the last one (not specified in S17). The number of repetitions (i.e., the number of intermediate recrystallization treatments) is, for example, 5 to 10 times.

[0062] In the repeated heating and drawing processes, a drawing die with a smaller aperture than the drawing die used in the previous drawing is used. Furthermore, in the repeated heating and drawing processes, the tungsten wire is heated to a lower temperature than the heating temperature used in the previous drawing. For example, the heating temperature in the previous drawing process preceding the final drawing process is lower than the heating temperature before that, for example, 400°C.

[0063] If the wire drawing process is the last one ("Yes" in S17), heated wire drawing is performed as the final wire drawing (S18). As a result, tungsten wire with a diameter of less than about 40 μm is obtained.

[0064] Next, the drawn tungsten wire is electrolytically polished (S19). Electrolytic polishing is performed, for example, by immersing the tungsten wire and the counter electrode in an electrolyte such as an aqueous sodium hydroxide solution to create a potential difference between the tungsten wire and the counter electrode. Through electrolytic polishing, the wire diameter of the tungsten wire can be finely adjusted.

[0065] After electrolytic polishing, the tungsten wire undergoes a final heat treatment (S20). The temperature of the final heat treatment is, for example, 1200℃~1700℃.

[0066] Through the above processes, the tungsten wire 10 of this embodiment is manufactured. The length of the tungsten wire 10 manufactured through the above processes is, for example, 50 km or more, making it suitable for industrial use. The tungsten wire 10 is cut to suitable lengths according to the method used and used in the manufacture of twisted yarn 1 or various fiber products. Thus, in this embodiment, the industrial mass production of the tungsten wire 10 can be achieved, primarily for use in fiber products.

[0067] It should be noted that the various processes shown in the manufacturing method of tungsten wire 10 are performed, for example, inline. Specifically, the multiple drawing dies used in step S15, etc., are arranged on the production line in order of decreasing aperture. Furthermore, heating devices such as burners are arranged between each drawing die. The heating devices are arranged for heating the wire drawing and intermediate recrystallization processes. Additionally, downstream of the drawing die used in step S15 (the subsequent process side), the multiple drawing dies used in step S18 are arranged in order of decreasing aperture, and an electrolytic grinding device and a heating device for final heat treatment are arranged downstream of the drawing die with the smallest aperture. It should be noted that each process can also be performed individually.

[0068] [Example]

[0069] Next, examples and comparative examples of tungsten wire 10 manufactured according to the above-described manufacturing method will be described. Regarding the tungsten wire 10 of Examples 1-15 and Comparative Examples 1-8 shown below, various parameters in the manufacturing method (specifically, wire diameter, type and amount of additives, final heat treatment temperature, and number of intermediate recrystallization treatments) are appropriately different. Specifically, as shown in Tables 1 and 2 below.

[0070] [Table 1]

[0071]

[0072] [Table 2]

[0073]

[0074] Figure 3 This is a scatter plot showing the relationship between the elongation and tensile strength of the tungsten wire 10 in the embodiments and comparative examples. Figure 3 In the figure, the horizontal axis represents the elongation of tungsten wire 10 [%), and the vertical axis represents the tensile strength of tungsten wire 10 [MPa].

[0075] The diameter of the tungsten wire 10 in Examples 1-15 is all less than 40 μm. Furthermore, as... Figure 3 As shown, the tungsten wire 10 in each embodiment falls within the range of tensile strength of 1600 MPa to 2400 MPa and elongation of 5% to 16%. It should be noted that... Figure 3 In the diagram, the ranges for tensile strength and elongation are indicated by dashed lines. In contrast, the tungsten wire 10 of Comparative Examples 1-8 is located in... Figure 3 Outside the area indicated by the dashed line.

[0076] The following describes the results of a study on the parameters in the manufacturing method of the tungsten wire 10, which are considered to be factors contributing to the differences between the example and the comparative example.

[0077] <Additives>

[0078] First, the types and amounts of alloying elements added (content in tungsten wire 10) are explained. Table 1 shows that increasing the amount of alloying elements tends to increase elongation.

[0079] Furthermore, in Table 1, Examples 5 and 9 had the same wire diameter of 35 μm, Re as the additive, a final heat treatment temperature of 1600 °C, and 6 intermediate recrystallization treatments. All parameters except for the amount of Re added were identical. A comparison of Examples 5 and 9 shows that Example 9, with a higher amount of Re added, had a higher elongation and lower tensile strength compared to Example 5.

[0080] Therefore, increasing the amount of alloying elements can improve elongation while maintaining a tensile strength of over 1600 MPa. Conversely, decreasing the amount of alloying elements can improve tensile strength while maintaining an elongation of over 5%.

[0081] Furthermore, when Ru is used as an additive as in Example 11, even if the amount added is about one order of magnitude smaller than that added in the case of Re, both elongation and tensile strength can be ensured to a high degree.

[0082] Final heat treatment temperature

[0083] Next, the final heat treatment temperature will be explained. As shown in Table 1, if the final heat treatment temperature is higher, there is a tendency for the elongation to increase.

[0084] Furthermore, in Examples 1 and 2 of Table 1, the wire diameter was 11 μm, the additive was Re, the addition amount was 5% by mass, the number of intermediate recrystallization treatments was 8, and the parameters other than the final heat treatment temperature were the same. Comparing Examples 1 and 2 reveals that Example 2, with its higher final heat treatment temperature, exhibited higher elongation and lower tensile strength compared to Example 1. Examples 5 and 6 also showed the same tendency, with the same parameters other than the final heat treatment temperature. The same tendency was also observed in Examples 7-9, Examples 12 and 13, and Examples 14 and 15, with the same parameters other than the final heat treatment temperature. This same tendency was observed in both the 11 μm wire diameter (Examples 1 and 2) and the 35 μm wire diameter (Example 5, etc.).

[0085] Based on this, it can be seen that regardless of the diameter of the tungsten wire 10, increasing the final heat treatment temperature can improve the elongation while ensuring a tensile strength of 1600 MPa or higher. Conversely, regardless of the diameter of the tungsten wire 10, decreasing the final heat treatment temperature can improve the tensile strength while ensuring an elongation of 5% or higher.

[0086] Furthermore, the parameters of Comparative Examples 1 and 2 in Table 2 are the same as those of Examples 12 and 13 in Table 1, except for the final heat treatment temperature. However, the elongation of Comparative Examples 1 and 2, whose final heat treatment temperature is below 1400°C, becomes less than 5%. Thus, it can be said that, with a wire diameter of at least 35 μm, the addition of 5% by mass of Re, and five intermediate recrystallization treatments, by performing the final heat treatment at a temperature greater than 1400°C, preferably above 1500°C, it is possible to set the elongation to 5% or more.

[0087] Furthermore, when Ru is used as an additive as in Example 11, both elongation and tensile strength can be well ensured even when the final heat treatment temperature is 1200°C.

[0088] <Number of intermediate recrystallization treatments>

[0089] Next, the number of intermediate recrystallization treatments will be explained. Table 1 shows that increasing the number of intermediate recrystallization treatments tends to increase the elongation. Specifically, if the number of intermediate recrystallization treatments is 5 or more, the elongation can be set to 5% or more.

[0090] Furthermore, in Table 1, Examples 6 and 10 share the same wire diameter of 35 μm, Re as the additive, an addition amount of 3% by mass, a final heat treatment temperature of 1700°C, and all parameters except for the number of intermediate recrystallization treatments. A comparison of Examples 6 and 10 reveals that Example 6, with its higher number of intermediate recrystallization treatments, exhibits higher elongation but lower tensile strength compared to Example 10. Conversely, reducing the number of intermediate recrystallization treatments allows for a higher tensile strength while maintaining an elongation of 5% or more.

[0091] Furthermore, Comparative Example 4 in Table 2 has the same parameters as Examples 6 and 10 in Table 1, except for the number of intermediate recrystallization treatments. However, in this case, Examples 6 and 10, which had 5 or more intermediate recrystallization treatments, showed higher elongation and tensile strength compared to Comparative Example 4, which had 3 intermediate recrystallization treatments. This indicates that when the number of intermediate recrystallization treatments is less than 3, it is impossible to set the elongation to 5% or more.

[0092] Furthermore, as shown in Table 1, the required number of intermediate recrystallization treatments varies depending on the wire diameter. Specifically, when the wire diameter is in the range of 11 μm to 18 μm, the elongation of the tungsten wire 10 becomes 5% or more when the number of intermediate recrystallization treatments is 8 or more. On the other hand, when the wire diameter is 35 μm, the elongation of the tungsten wire 10 becomes 5% or more when the number of intermediate recrystallization treatments is 5 or more. From this, it can be concluded that to obtain a finer tungsten wire 10, the number of intermediate recrystallization treatments should be increased compared to obtaining a coarser tungsten wire 10.

[0093] It should be noted that recrystallization treatment refers to the rearrangement of crystals through heat treatment. Recrystallization treatment promotes the dispersion of solid-solution elements such as Re or Ru, which helps increase the elongation when the tungsten wire 10 is made thinner. Thus, by applying heat to the tungsten wire 10 as a recrystallization treatment during the manufacturing process, the dispersion of alloying elements (Re or Ru) in the tungsten wire 10 is improved. This suppresses the uneven presence of alloying elements, thus achieving a balance between increased tensile strength and increased elongation in the fine tungsten wire 10.

[0094] It should be noted that this explanation uses the case where the diameter of the tungsten wire 10 is less than 40 μm and the tensile strength is less than 2400 MPa as an example, but it is not limited to this. The diameter of the tungsten wire 10 can also be 40 μm or more. Furthermore, the tensile strength of the tungsten wire 10 can also be 2400 MPa or more.

[0095] [Relationship between elongation of organic fibers and tungsten wire]

[0096] Next, the relationship between the elongation of organic fiber 20 and the elongation of tungsten wire 10 will be explained.

[0097] Generally speaking, organic fiber 20 has a higher elongation rate than tungsten wire 10. Simply put, organic fiber 20 is easy to elongate, while tungsten wire 10 is not. Therefore, if organic fiber 20 elongates due to external stress such as stretching, bending, or twisting, and tungsten wire 10 does not follow suit and elongate, a portion of tungsten wire 10 may break.

[0098] Figure 4 This is a schematic diagram showing the state of the twisted yarn 1 before and after elongation in this embodiment. Figure 4 (a) and (b) represent a three-dimensional view and a side view before the twisted yarn 1 is stretched, and (c) and (d) represent a three-dimensional view and a side view after the twisted yarn 1 is stretched.

[0099] exist Figure 4 In (a), Rp represents the diameter of the organic fiber 20. Furthermore, Lp represents the spacing of the coils of the tungsten wire 10. For example... Figure 4As shown in (c), when the organic fiber 20 is elongated, the diameter of the organic fiber 20 becomes Rp'. Although the length of the organic fiber 20 increases with the elongation of the organic fiber 20, the volume does not change. Therefore, the diameter Rp' of the elongated organic fiber 20 must become smaller than the diameter Rp of the organic fiber 20 before elongation.

[0100] When the elongation of the tungsten wire 10 follows the elongation of the organic fiber 20, the spacing of the coils of the elongated tungsten wire 10 becomes Lp'. The spacing Lp' of the coils of the elongated tungsten wire 10 is greater than the spacing Lp of the coils of the tungsten wire 10 before elongation.

[0101] like Figure 4 As shown in (b), if the length of the tungsten wire 10 before elongation is set to Lw, then Lw is represented by the following equation (1). It should be noted that π is the mathematical constant pi.

[0102] (I)

[0103] like Figure 4 As shown in (d), if the length of the elongated tungsten wire 10 is set to Lw', then Lw' is represented by the following equation (2).

[0104] (2)

[0105] If the elongation of the organic fiber 20 is set as Tp and the elongation of the tungsten wire 10 is set as Tw, then Tp and Tw are represented by the following equations (3) and (4), respectively.

[0106] (3)

[0107] (4)

[0108] By using transformation equations (1) to (4), Tw is represented by Rp, Lp and Tp and by the following equation (5).

[0109] (5)

[0110] The value of Tw shown in the above equation (5) is the elongation rate Tw required for the tungsten wire 10 to continuously follow and elongate when the organic fiber 20 elongates at an elongation rate Tp. Therefore, when the elongation rate Tw of the tungsten wire 10 is greater than or equal to the right side of the above equation (5), it means that the tungsten wire 10 can follow the elongation of the organic fiber 20.

[0111] Here, a specific example of the elongation Tp of organic fiber 20 is used. Figure 5 Please provide an explanation.

[0112] Figure 5 This is a graph showing the maximum elongation Tp for each type of fiber that can be used as organic fiber 20. (See figure) Figure 5 As shown, the maximum elongation Tp of organic fiber 20 varies greatly depending on the material. Generally, hemp (flax) is the organic fiber 20 with the lowest elongation Tp, with a maximum Tp value of 1.5% to 2.3%. Polypropylene is a relatively easy-to-stretch material, with a maximum elongation Tp value of 25% to 60%. For other materials, the maximum elongation Tp value is generally in the range of 10% to 30%.

[0113] Figure 5 The maximum elongation Tp shown is a rough estimate under standard conditions. For example, in a humid environment, the maximum elongation Tp increases because the organic fiber 20 becomes more easily stretched. Similarly, the maximum elongation Tp generally increases in the case of multifilaments. It is estimated that if the unevenness of elongation Tp caused by such environments is taken into account, the maximum elongation Tp of the organic fiber 20 can be taken as... Figure 5 It is approximately 1.5 to 2.0 times the value shown.

[0114] Next, the specific values ​​of Lp / Rp are used... Figure 6 Please provide an explanation.

[0115] Figure 6 This is a diagram illustrating an example of the Lp / Rp ratio of the twisted yarn 1 when multiple organic fibers 20 of different diameters are each wound with a specified number of turns around a tungsten wire 10. Figure 6 In the examples of coating processing, four cases are shown: 21 and 18 rolls per inch, and 100 and 1000 rolls per meter. Furthermore, as examples of organic fiber 20, three types are shown: wire diameter Rp of 0.3 mm, 0.8 mm, and 1.2 mm.

[0116] The Lp / Rp values ​​calculated from these combinations fall within the range of 0.83 to 33.33. Furthermore, the typical Lp / Rp value is in the range of 3 to 5.

[0117] Given the above, the elongation Tp of the organic fiber 20 can be expected to be at most 100% (i.e., elongated to twice its original length), and the value of Lp / Rp can be expected to be at most 100. Below, the results of calculating the elongation Tw of the tungsten wire 10 relative to the elongation Tp of the organic fiber 20 for each ratio (Lp / Rp) of Rp using the above formula (5) will be presented. Figure 7 and Figure 8 middle.

[0118] Figure 7 and Figure 8 These are graphs representing the required elongation Tw of tungsten wire 10 within a specified range for the elongation Tp of organic fiber 20. Figure 7 and Figure 8 In the table, the values ​​of Lp / Rp are arranged in the row direction, the values ​​of Tp are arranged in the column direction, and the value of Tw is recorded in the cell at the intersection of the row and column. Figure 7 In the diagram, the value of Tp is displayed in 2% increments, ranging from 0% to 40%. Figure 8 In this context, the value of Tp is displayed as a range from 0% to 100% on a 5% scale. Figure 7 and Figure 8 In the figure, the values ​​of Lp / Rp are shown as 1, 2, 2.5, 3, 5, 10, 50 and 100. The smaller the value of Lp / Rp, the narrower the tungsten wire 10 is wound, and the larger the value of Lp / Rp, the wider the tungsten wire 10 is wound.

[0119] The tungsten wire 10 of this embodiment achieves an elongation of 5% or more Tw through the manufacturing method described above. Figure 7 and Figure 8 In the middle, if the elongation Tw of tungsten wire 10 is 5%, then a shading line is marked to indicate the range that can be followed without interruption (i.e., the range where Tw is less than 5% as calculated using Equation (5)).

[0120] like Figure 7 and Figure 8 As shown, it can be seen that if the elongation Tp of the organic fiber 20 is less than 5%, the tungsten wire 10 can follow continuously regardless of the value of Lp / Rp. Figure 5 As shown, regarding the elongation of hemp, the material with the lowest elongation as organic fiber 20, even considering the dependence on the environment and taking into account that it can be twice the value, the maximum is 4.6% (=2.3×2)%. That is, it can be seen that when hemp is used as organic fiber 20, the tungsten wire 10 can follow continuously regardless of the spacing at which it is wound.

[0121] Furthermore, when Lp / Rp is 2, such as Figure 8 As shown, the tungsten wire 10 can follow the organic fiber 20 up to an elongation Tp of 45%. Therefore, referring to... Figure 5 It can be seen that it is capable of handling not only hemp, but also the elongation of various organic fibers such as cotton, silk, rayon, and polyester. With an Lp / Rp ratio of 2.5, such as... Figure 7 As shown, the tungsten wire 10 can follow the organic fiber 20 up to an elongation Tp of 26%. Therefore, referring to... Figure 5It can be seen that it can handle not only hemp but also cotton elongation. As Lp / Rp increases, the range of elongation Tp of organic fibers 20 that the tungsten wire 10 can follow narrows, but it can handle more types of organic fibers 20 depending on the usage environment.

[0122] Furthermore, regarding the tungsten wire 10 of Example 13 described above, an elongation of 16% Tw was achieved. Figure 7 and Figure 8 In the middle, if the elongation Tw of tungsten wire 10 is 16%, the marked point is shaded to indicate the range that can be followed without line (i.e., the range where Tw calculated using Equation (5) is less than 16% (the range less than 5% is shaded with diagonal lines)).

[0123] like Figure 7 As shown, if the elongation Tp of the organic fiber 20 is 16% or less, the tungsten wire 10 can continuously follow regardless of the value of Lp / Rp. Therefore, the tungsten wire 10 can continuously follow a wider variety of organic fibers 20.

[0124] like Figure 5 As shown, few organic fibers 20 achieve an elongation of over 50%. With an Lp / Rp ratio of 2, such as Figure 8 As shown, the tungsten wire 10 can maintain the elongation Tp of the organic fiber 20 up to 80%. Furthermore, with Lp / Rp of 2.5, the tungsten wire 10 can maintain the elongation Tp of the organic fiber 20 up to 55%. That is, it can be seen that with a tungsten wire 10 having an elongation Tw of 16%, it is capable of handling... Figure 5 The image shows almost all types of organic fibers 20.

[0125] As Lp / Rp increases, the range of elongation Tp of organic fibers 20 that the tungsten wire 10 can follow narrows, but it can accommodate a wider variety of organic fibers 20 depending on the application environment. For example... Figure 7 and Figure 8 As shown, the tungsten wire 10 with an elongation of 16% is able to cope with the situation even if the elongation Tp of the organic fiber 20 is about 3 times larger than that of the tungsten wire 10 with an elongation of 5%.

[0126] By increasing Lp / Rp, the length of the tungsten wire 10 used in the twisted yarn 1 can be shortened. Therefore, the amount of tungsten wire 10 used can be reduced, thus achieving lightweighting and cost reduction of the twisted yarn 1.

[0127] [Fiber products with twisted yarn]

[0128] Next, for those with Figure 1 A specific example of the fiber product of the twisted yarn 1 shown will be explained.

[0129] Fiber products are selected from textiles, woven fabrics, braided fabrics, twisted yarns, and sewing yarns. Below, as an example of a fiber product, [the following section discusses products possessing...]. Figure 1 The gloves shown are made of twisted yarn 1 and are used for... Figure 9 Please provide an explanation.

[0130] Figure 9 This is a schematic diagram of a fiber article 100 comprising the twisted yarn 1 of the embodiment. Figure 9 As shown, the fiber product 100 is, for example, a glove. It should be noted that, in Figure 9 In the diagram, only the eyelets at the tips of the thumb and forefinger are schematically shown, but the entire fiber product 100 is eyelet-shaped.

[0131] The fiber product 100 is, for example, a work glove, having a palm and five fingers. The fiber product 100 is manufactured by weaving using twisted yarn 1 as both warp and weft. The fabric structure of the fiber product 100 is, for example, a twill weave (specifically, a four-thread twill weave with a 2 / 2 twill structure). Specifically, as... Figure 9 As shown, a fiber product 100 is formed by alternating the crossing of multiple twisted yarns 1 constituting the warp yarns and multiple twisted yarns 1 constituting the weft yarns in pairs.

[0132] It should be noted that the fabric structure of the fiber product 100 is not limited to this, and may also be other twill weaves such as three-thread twill or four-thread twill with a 3 / 1 twill structure. Alternatively, the fabric structure of the fiber product 100 may also be plain weave or satin weave. In addition, the fiber product 100 may also be manufactured by using twisted yarn 1 as the spinning yarn and performing knitting or other knitting processes with a specified gauge.

[0133] Figure 9 The fiber article 100 shown can be used, for example, for scratch resistance or vital sign sensing. For instance, the fiber article 100 can sense the wearer's body temperature or pulse as a vital sign. Specifically, the tungsten wire 10 of the fiber article 100 functions as a terminal for sensing vital signs. That is, the tungsten wire 10 can detect the weak current emitted by the wearer.

[0134] Alternatively, the fiber product 100 may also have terminals for sensing vital signs. In this case, the tungsten wire 10 may also function as wiring to electrically connect the terminal to the signal processing circuit.

[0135] In addition, the fiber article 100 can also be used for heating purposes. Specifically, an electric current can be passed through the tungsten wire 10 contained in the fiber article 100 to generate heat.

[0136] Besides gloves, fiber products can also include clothing, hats and other headwear, socks, and footwear. Alternatively, fiber products can also include towels, handkerchiefs, blankets, and bed sheets.

[0137] It should be noted that the fiber product does not necessarily need to have twisted yarn 1; it is sufficient to combine tungsten wire 10 with organic fiber 20. Specifically, the fiber product can also be a nonwoven fabric manufactured by using tungsten wire 10 and organic fiber 20 as threads for nonwoven fabric processing. In addition, the fiber product can also be a product made by gathering twisted yarn 1 into a cotton-like (cotton-like) shape. Alternatively, the fiber product can also be a product made by sewing (embroidering or sewing) tungsten wire 10 onto textiles, woven fabrics, or braided fabrics made using organic fibers.

[0138] [The flexibility of tungsten wire]

[0139] Next, regarding the bendability of tungsten wire 10, use... Figure 10 Please provide an explanation.

[0140] like Figure 1 As shown, the tungsten wire 10, being wound onto the organic fiber 20, is required to withstand bending above a specified curvature. Furthermore, as... Figure 9 As with the fiber products 100 shown, in order to withstand various processing such as textile and weaving, they are also required to withstand bending with a specified curvature or higher. Therefore, the inventors of this application conducted a winding test to confirm the bendability of the tungsten wire 10. The content and results of the winding test will be described below.

[0141] Figure 10 This is a diagram illustrating a general outline of a winding test of the tungsten wire 10 according to an embodiment. In the winding test, the tungsten wire 10 is wound around a rod-shaped core material 200 with a circular cross-section and a uniform diameter to confirm whether the tungsten wire 10 breaks or peels off on the surface. The diameter R of the cross-section of the core material 200 used in the winding test and the diameter φ of the tungsten wire 10 are specified, for example, according to the specifications of the fiber product manufactured using the tungsten wire 10 and the organic fiber 20.

[0142] Figure 11This is a cross-sectional view of a fiber product (metal mesh) 110 woven using tungsten wire 10 and organic fiber 20 according to this embodiment. The fiber product 110 is a metal mesh woven using tungsten wire 10 and organic fiber 20 as warp and weft yarns, respectively. As an example of the fiber product 110, it is assumed that a 900-mesh metal mesh is manufactured using tungsten wire 10 and organic fiber 20 with a diameter of 12 μm. It should be noted that "mesh" here refers to the number of threads between 25.4 mm (1 inch). In this case, the distance between two adjacent tungsten wires 10, i.e., the spacing, is 28.2 μm (=25.4 mm ÷ 900). It is assumed that the distance between two adjacent tungsten wires 10 is the same as the distance between two adjacent organic fibers 20.

[0143] In this case, such as Figure 11 As shown, the radius of curvature Rc of the tungsten wire 10 is 19.6 μm. It should be noted that the radius of curvature Rc is defined based on the central axis of the tungsten wire 10 (the dashed line in the figure). Furthermore, the inner radius of curvature Ri of the tungsten wire 10 is 13.6 μm. The inner radius of curvature Ri is defined based on the curved inner surface of the tungsten wire 10. That is, if the tungsten wire 10 does not break or experience surface peeling when set to a radius of curvature Rc of 19.6 μm or less and an inner radius of curvature Ri of 13.6 μm or less, it can be used as the warp and weft yarn of the fiber product 110.

[0144] In the winding test, conditions exceeding the limits of what can be woven into a metal mesh are used. As a result of the winding test conducted under conditions exceeding the limits of what can be woven, the tungsten wire 10 used in the test can be used to stably manufacture fiber products (metal mesh) 110 without causing breakage (wire breakage) or surface peeling of the tungsten wire 10.

[0145] For example, the condition for tungsten wires 10 with a diameter of 12 μm to be in contact with each other is a 1222 mesh case. That is, it is impossible to manufacture metal mesh with a mesh number of 1222 or higher. As a condition for the winding test, it is assumed that the tungsten wires 10 are 12 μm and the fiber product 110 is 1324 mesh.

[0146] It should be noted that the breakage of the tungsten wire 10 is caused by the strain of the material constituting the tungsten wire 10, therefore, tungsten wires 10 with different diameters can be used for study. For example, if the 12μm and 1324 mesh condition is converted to a 35μm tungsten wire 10, it becomes 454 mesh (=1324 mesh × 12μm ÷ 35μm). Under this condition, the radius of curvature Rc is 31μm, and the inner radius of curvature Ri is 13.5μm.

[0147] The inventors of this application used a core material 200 with a diameter R = 27 μm and a tungsten wire 10 with a diameter φ = 35 μm in the winding test. The inner radius of curvature Ri of the tungsten wire 10 wound on the core material 200 is 13.5 μm (=R÷2), and the radius of curvature Rc is 31.0 μm (=Ri+φ÷2). Therefore, if no breakage or surface peeling occurs in the winding test under these conditions, it means that a 900-mesh fiber product (metal mesh) 110 can be manufactured using a 12 μm tungsten wire 10.

[0148] Table 3 below shows the results of winding tests conducted on Comparative Examples 9 and 10 and Example 16. It should be noted that the wire diameter was 35 μm, the alloying element used as an additive was Re, and the addition amount was 5% by mass. Furthermore, the intermediate recrystallization treatment was performed 6 times in all cases.

[0149] [Table 3]

[0150]

[0151] Figure 12A This is a diagram showing the appearance of the tungsten wire of Example 16 after the winding test. Figure 12B It is Figure 12A The image is obtained by magnifying a portion of it. For example... Figure 12A and Figure 12B As shown, in Example 16, there was neither breakage of the tungsten wire nor surface peeling.

[0152] Figure 13A This is a diagram showing the appearance of the tungsten wire of Comparative Example 10 after the winding test. Figure 13B It is Figure 13A The image is obtained by magnifying a portion of it. For example... Figure 13A and Figure 13B As shown, in Comparative Example 10, although there was no breakage of the tungsten wire, slight surface peeling occurred. Therefore, although it is possible to manufacture fiber products (metal mesh) 110 with an elongation of 4%, an elongation of 5% or more is preferred for manufacturing higher quality fiber products 110.

[0153] It should be noted that the wire diameter and mesh spacing of the tungsten wire 10 are not limited to the examples mentioned above.

[0154] [Effects, etc.]

[0155] As described above, a twisted yarn 1, as an example of a fiber product, comprises: a tungsten wire 10 with an elongation of 5% or more; and an organic fiber 20 combined with the tungsten wire 10.

[0156] As a result, the tungsten wire 10 becomes easier to follow the elongation of the organic fiber 20, thus suppressing the breakage of the tungsten wire 10.

[0157] In addition, for example, the diameter of the tungsten wire 10 is less than 40 μm.

[0158] Therefore, it is easy to twist the organic fiber 20, which can improve the productivity of the twisted yarn 1 and the fiber products manufactured using the twisted yarn 1.

[0159] Furthermore, for example, tungsten wire 10 is an alloy wire made of tungsten and at least one metallic element other than tungsten. Furthermore, for example, the at least one metallic element is an element contained in Group 7 or Group 8.

[0160] Therefore, by dispersing the alloying elements in the tungsten wire 10 in a non-uniform manner, the tensile strength can be maintained at a high level and the elongation can be improved.

[0161] Furthermore, for example, the tungsten wire 10 does not break even when bent to a specified value where its radius of curvature is below 13.6 μm.

[0162] Therefore, it is possible to stably manufacture metal mesh with a mesh size of 900 as described above.

[0163] Furthermore, for example, the organic fiber 20 is at least one fiber selected from synthetic fibers, natural fibers, and regenerated fibers. When the organic fiber 20 is a monofilament, the elongation of the organic fiber 20 is 70% or less.

[0164] Therefore, the elongation of the organic fiber 20 will not be too high, so the tungsten wire 10 becomes easy to follow without breaking.

[0165] Furthermore, for example, tungsten wire 10 and organic fiber 20 constitute twisted yarn 1. Furthermore, for example, twisted yarn 1 is a core-spun yarn with organic fiber 20 as the core yarn and tungsten wire 10 as the sheath yarn.

[0166] Therefore, various fiber products can be manufactured using the twisted yarn 1 containing tungsten wire 10. For example, the fiber product is selected from textiles, woven fabrics, braided fabrics, twisted yarns, and sewing yarns.

[0167] (other)

[0168] The fiber products of the present invention have been described above based on the embodiments described above, but the present invention is not limited to the embodiments described above.

[0169] Furthermore, for example, the tungsten wire 10 can also be made of tungsten doped with potassium (K). The doped potassium is present at the grain boundaries of the tungsten crystals. The tungsten content in the tungsten wire 10 is, for example, 99% by mass or more.

[0170] The potassium content in tungsten wire 10 is less than 0.01% by mass, but is not limited to this. For example, the potassium content in tungsten wire 10 can also be from 0.005% to 0.010% by mass.

[0171] The smaller the diameter of tungsten wire made from potassium-doped tungsten (potassium-doped tungsten wire), the higher its tensile strength. The diameter, elastic modulus, and tensile strength of potassium-doped tungsten wire are the same as in the embodiments described above.

[0172] In this way, by containing trace amounts of potassium in the tungsten wire, the growth of grains in the radial direction of the tungsten wire can be suppressed. That is, the width of the surface grains can be reduced, thus improving the tensile strength.

[0173] Potassium-doped tungsten wires can be manufactured using the same manufacturing method as in the embodiments, by using potassium-doped tungsten powder instead of tungsten powder.

[0174] In addition, for example, an oxide film or a nitride film may be coated on the surface of the tungsten wire 10.

[0175] Furthermore, for example, in the above embodiment, a twisted yarn 1 composed of one tungsten wire 10 and one organic fiber 20 was shown, but the number of tungsten wires 10 and organic fibers 20 combined is not limited to this. For example, two or more tungsten wires 10 may be combined with one organic fiber 20. Specifically, the twisted yarn 1 may also be a core-spun yarn formed by winding two or more tungsten wires 10 together with one organic fiber 20 as the core yarn. The twisted yarn 1 may also be a double-twisted yarn formed by twisting one organic fiber 20 together with two or more tungsten wires 10.

[0176] Alternatively, one tungsten wire 10 can be combined with two or more organic fibers 20. Specifically, the twisted yarn 1 can also be a core-spun yarn formed by using two or more organic fibers 20 together as the core yarn and winding them around one tungsten wire 10. The twisted yarn 1 can also be a double-twisted yarn formed by twisting two or more organic fibers 20 together with one tungsten wire 10.

[0177] Alternatively, two or more tungsten wires 10 can be combined with two or more organic fibers 20. Specifically, the twisted yarn 1 can also be a core-spun yarn formed by using two or more organic fibers 20 together as the core yarn and winding two or more tungsten wires 10 together. The twisted yarn 1 can also be a double-twisted yarn formed by twisting two or more organic fibers 20 together with two or more tungsten wires 10.

[0178] Furthermore, for example, instead of multiple tungsten wires 10, tungsten wires 10 and metal wires different from tungsten wires 10 can be used to manufacture the twisted yarn 1. For example, tungsten wire and molybdenum wire can also be used.

[0179] Furthermore, when using multiple organic fibers 20, the multiple organic fibers 20 can be manufactured using the same material as each other, or they can be manufactured using different materials.

[0180] Furthermore, for example, in the above embodiments, an example was shown where the diameter of the tungsten wire 10 was smaller than the diameter of the organic fiber 20, but this is not a limitation. For example, the diameter of the tungsten wire 10 could also be equal to the diameter of the organic fiber 20.

[0181] Furthermore, the following methods are also included in this invention: methods obtained by implementing various modifications to each embodiment as conceived by those skilled in the art; methods implemented by arbitrarily combining the constituent elements and functions of each embodiment without departing from the spirit of this invention.

[0182] Explanation of symbols

[0183] 1-twist yarn (fiber products)

[0184] 10 Tungsten wire

[0185] 20 Organic Fibers

[0186] 100 and 110 fiber products

Claims

1. A twisted yarn, comprising: Tungsten wire with an elongation of 5% or more; and Organic fibers combined with the tungsten wire, The tungsten wire is an alloy wire made of tungsten and at least one other metallic element different from tungsten. The tungsten wire contains more than 90% by mass of tungsten. The at least one metallic element is rhenium (Re) or ruthenium (Ru). In the case of rhenium-tungsten alloy wire, the rhenium content is 0.1% to 10% by mass. In the case of ruthenium-tungsten alloy wire, the ruthenium content is 0.05% to 0.3% by mass. The tensile strength of the tungsten wire is 1600MPa to 2400MPa.

2. The twisted yarn according to claim 1, wherein, The diameter of the tungsten wire is less than 40 μm.

3. The twisted yarn according to claim 1, wherein, The tungsten wire will not break even if it is bent to a specified radius of curvature of less than 13.6 μm.

4. The twisted yarn according to any one of claims 1 to 3, wherein, The organic fiber is selected from at least one type of fiber chosen from synthetic fibers, natural fibers, and regenerated fibers. When the organic fiber is a monofilament, the elongation of the organic fiber is less than 70%.

5. The twisted yarn according to any one of claims 1 to 3, wherein, The twisted yarn is a core-spun yarn with the organic fiber as the core yarn and the tungsten wire as the sheath yarn.

6. A fiber article comprising the twisted yarn according to any one of claims 1 to 5.

7. The fiber product according to claim 6, wherein it is selected from textiles, woven fabrics and braided fabrics.

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