Method for manufacturing a fabric for clothing and fabric for clothing

Abstract

The present application provides a clothes fabric manufacturing method for adjusting heat retention and a clothes fabric. The clothes fabric manufacturing method is characterized by comprising: a defibration process (S2) of defibrating a raw material (C) in a dry manner to generate fibers; a mixing process (S3) of mixing an additive to the fibers obtained in the defibration process (S2) to generate a mixture; a piling process (S4) of piling the mixture on a fabric (N1) serving as a first layer (L1) having air permeability in air to generate a web (W) serving as a second layer (L2); a forming process (S5) of overlapping the fabric (N1) and the web (W) and performing heating and pressurization to perform forming; a pasting process (S6) of pasting a fabric (N3) serving as a third layer (L3) on at least one of the first layer (L1) and the second layer (L2); and a coating process (S7) of coating a treatment agent for improving heat retention to the third layer (L3).

Description

Technical Field

[0001] This invention relates to a method for manufacturing clothing fabric and the clothing fabric itself. Background Technology

[0002] In recent years, in order to address problems such as resource depletion and increased waste, a mechanism and technology for reusing used clothing has been researched. For example, Patent Document 1 discloses a technology for dry-splitting fabric to produce fiber sheets.

[0003] However, the technology described in Patent Document 1, when applied to the manufacture of clothing fabrics, presents the problem of difficulty in altering the insulation properties of the manufactured fabric. The required insulation properties of clothing vary depending on its intended use. The aforementioned technology does not address the adjustment of insulation properties in the fiber sheet to be manufactured. Therefore, a method for manufacturing clothing fabrics that adjusts insulation properties is needed.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2023-111178 Summary of the Invention The method for manufacturing fabric for clothing is characterized by comprising: a desiccation step, in which fabric is desiccated in a dry manner to generate fibers; a blending step, in which additives are mixed with the fibers obtained in the desiccation step to generate a mixture; a stacking step, in which the mixture is stacked in air on a breathable fabric to form a first layer to generate a sheet to form a second layer; a forming step, in which the fabric to form the first layer and the sheet are overlapped and heated and pressed to form a shape; a bonding step, in which a fabric to form a third layer is bonded to at least one of the first layer and the second layer; and a coating step, in which a treatment agent for improving heat retention is applied to the third layer.

[0005] The fabric for clothing is characterized by comprising: a first layer that is breathable; a second layer consisting of a sheet of material obtained by stacking a mixture of fibers and additives in the air, the fibers being obtained by dry unwinding the fabric; and a third layer that is bonded to at least one of the first and second layers and coated with a treatment agent that improves moisture retention. Attached Figure Description

[0006] Figure 1 This is a schematic cross-sectional view illustrating the structure of the clothing fabric involved in the embodiment.

[0007] Figure 2 A schematic cross-sectional view to show other ways of using fabric for clothing.

[0008] Figure 3A schematic cross-sectional view to show other ways of using fabric for clothing.

[0009] Figure 4 A flowchart illustrating the manufacturing process of fabrics for clothing.

[0010] Figure 5 This is a schematic diagram illustrating the structure of a fabric manufacturing apparatus used in the manufacture of clothing fabrics. Detailed Implementation

[0011] In the embodiments described below, a multi-layered garment fabric and its manufacturing method are illustrated, and the description is provided with reference to the accompanying drawings. In the following drawings, the XYZ axes are labeled as mutually orthogonal coordinate axes as needed, and the direction pointed to by each arrow is designated as the + direction, and the direction opposite to the + direction is designated as the - direction. The Z-axis is an imaginary axis along the vertical direction, with the +Z direction designated as upward and the -Z direction as downward. For ease of illustration, the sizes of the components are slightly different from actual dimensions.

[0012] 1. Clothing fabric like Figure 1 As shown, the clothing fabric F1 involved in this embodiment has a multi-layer structure including a first layer L1, a second layer L2, and a third layer L3. Clothing fabric F1 is an example of the clothing fabric of the present invention and is manufactured by the clothing fabric manufacturing method described later. Because clothing fabric F1 has improved heat retention, it is suitable for, for example, outerwear.

[0013] The first layer L1 includes a substrate layer L1b and an adhesive layer L1a. The third layer L3 includes a substrate layer L3b and an adhesive layer L3a. In the garment fabric F1, the substrate layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, the second layer L2, the adhesive layer L3a of the third layer L3, and the substrate layer L3b of the third layer L1 are stacked sequentially from bottom to top. When the garment fabric F1 is processed into a garment, from the viewpoint of the garment's heat retention and breathability, it is preferable to use the third layer L3 on the outer side of the garment.

[0014] The thickness of the fabric F1 for clothing is appropriately set according to the purpose and shape of the clothing to which it is applied. While the thickness of the fabric F1 is not particularly limited, it is typically set to be between 0.30 mm and 2.00 mm. This improves both softness and strength in the fabric F1. Furthermore, since the first layer L1 and the third layer L3 are layered on top of the second layer L2, the strength of the fabric F1 can be ensured by making the second layer L2 relatively thin. In this specification, thickness refers to the dimension along the direction in which the first layer L1, the second layer L2, and the third layer L3 are layered, i.e., along the Z-axis.

[0015] The first layer, L1, is breathable. If the third layer, L3, is used on the outer side of the garment, that is, the inner side of the garment (the side facing the body), the feeling of stuffiness during wear is suppressed, thereby improving wearing comfort. Furthermore, in the manufacture of garment fabric F1, the breathability of the first layer, L1, promotes the accumulation of fibers, etc., that become the second layer, L2, onto the first layer, L1. Specifically, by drawing in air containing dispersed fibers through the first layer, the formation of a sheet containing fibers is promoted. The manufacturing method and process of garment fabric F1 will be described in the later section on garment fabric manufacturing methods.

[0016] In this specification, air permeability is defined as the amount of air passing through the test piece obtained by the JIS air permeability test (L 1096 2010 8.26.1 A method). In this specification, air permeability means that the air volume determined by the above test method is 10 cm³. 3 / cm 2 For cases lasting more than a second.

[0017] While the thickness of the first layer L1 is not particularly limited, it is preferably, for example, 0.01 mm or more and 0.20 mm or less. Accordingly, the softness and strength of the clothing fabric F1 can be improved.

[0018] The substrate layer L1b is breathable. The substrate layer L1b forms one surface of the garment fabric F1. The substrate layer L1b is a sheet containing polyester fabrics, woven fabrics, or nonwoven fabrics. Therefore, due to the superior strength of polyester, the thinness and strength of the garment fabric F1 can be increased.

[0019] The substrate layer L1b is not limited to being made of polyester; it may also be a sheet containing polyester and other resins, or a sheet made of resins other than polyester.

[0020] The adhesive layer L1a is located between the substrate layer L1b and the second layer L2. The adhesive layer L1a is used to bond the first layer L1 and the second layer L2 together, thereby ensuring the bonding strength between the first layer L1 and the second layer L2.

[0021] The adhesive layer L1a contains an adhesive. Examples of adhesive materials include well-known adhesives such as polyester resin, acrylic resin, silicone resin, and polyurethane resin, as well as epoxy, acrylic, cyanoacrylate, urethane, and vinyl acetate adhesives. The adhesive in the adhesive layer L1a may also be an adhesive that is cured by heat applied during the molding process in the manufacturing process of the garment fabric F1, as described later.

[0022] The adhesive layer L1a is also breathable. Specifically, the adhesive layer L1a is formed in a manner that does not impede the breathability of the first layer L1. Examples of such adhesive layer L1a include a form in which the adhesive material or adhesive described above is planarly coated into a mesh-like structure, and a form having multiple holes penetrating along the Z-axis.

[0023] Furthermore, the adhesive layer L1a is not a necessary structure, and the first layer L1 can also consist solely of the substrate layer L1b. In this case, the first layer L1 and the second layer L2 are bonded together by the adhesive effect of the additives contained in the second layer L2.

[0024] The first layer L1 can also be colored. If the substrate layer L1b and the adhesive layer L1a are formed from the materials described above, they are typically white. If the second layer L2 is colored, the hues of the first layer L1 and the second layer L2 will be significantly different. In this case, when the garment is made from fabric F1, the difference in hue between the first layer L1 and the second layer L2 will easily become noticeable. In contrast, if the first layer L1 is colored to a hue close to that of the second layer L2, the difference in hue will be less noticeable when the garment is made.

[0025] Furthermore, when the first layer L1 is used as the outer side of the garment, coloring the first layer L1 can enhance the design of the garment.

[0026] The coloring of the first layer L1 can be achieved using known methods such as digital printing (e.g., inkjet printing) and analog printing. The coloring of the first layer L1 can be performed either in advance during the manufacturing stage of the fabric that becomes the first layer L1, or during the manufacturing process of the garment fabric F1.

[0027] The second layer, L2, is a nonwoven fabric and contains multiple fibers obtained by debonding the fabric, as well as additives such as bonding materials. The second layer, L2, is composed of sheets of material formed by stacking multiple fibers in the air. In the following description, the multiple fibers after debonding will sometimes be referred to simply as fibers. Although details will be described later, the debonding process used to obtain the fibers is carried out in a dry manner. In this specification, "dry" refers to a process carried out in air, such as atmosphere, rather than in liquids such as water.

[0028] Fiber is one of the main components of the second layer L2, and together with the bonding materials, it affects the physical properties of the second layer L2, such as mechanical strength. From a resource recycling perspective, fibers obtained by debonding fabrics derived from old clothes are preferred. Types of fabrics include knitted fabrics, plain weave fabrics, and napped fabrics. Furthermore, non-woven fabrics may also be included.

[0029] Here, when old clothes are effectively utilized as a fiber material, fibers of various materials may be mixed in the second layer L2. Depending on the material and form of the fibers, the insulation properties of the resulting second layer L2 can sometimes change. That is, it has historically been difficult to adjust the insulation properties using the second layer L2. Furthermore, as mentioned above, since the first layer L1 is breathable, it is also difficult to adjust the insulation properties using the first layer L1. In contrast, the clothing fabric F1, through the third layer L3 coated with a treatment agent, allows for the adjustment of its insulation properties.

[0030] In addition, the insulation properties of the fabric F1 used in clothing can be adjusted not only by the third layer L3, but also by changing the thickness and density of the second layer L2. If the thickness and density of the second layer L2 are changed, the volume of the voids contained in the second layer L2 will change, thus making it easier to adjust the insulation properties.

[0031] As fibers, examples include natural fiber materials such as cotton, linen, wool, silk, and regenerated cellulose, as well as synthetic fibers such as polypropylene, polyester, and polyurethane.

[0032] Regarding fibers, one of them can be used alone, or two or more can be used in combination. In particular, among the aforementioned fiber materials, from the viewpoints of availability of old clothes, etc., and the physical properties of the fibers, the fabric preferably contains cotton or wool.

[0033] The weighted average fiber length of the unfibered fibers is preferably 0.5 mm or more and 2.0 mm or less. This prevents the fibers from becoming too short, allowing them to moderately intertwine, thereby improving the mechanical strength of the second layer L2. The weighted average fiber length is determined using a method based on ISO 16065-2:2007.

[0034] Considering the reuse of clothing made from garment fabric F1, the fibers of the second layer L2 are preferably white fibers. However, the fibers are not limited to white fibers and may also include fibers pre-dyed with dyes. On the other hand, the second layer L2 preferably does not contain coloring materials such as pigments. "Does not contain coloring materials" means that it does not contain coloring materials that have been intentionally added. The second layer L2 may also contain coloring materials such as pigment particles that have been unintentionally mixed in.

[0035] The preferred weight of the second layer L2 is 100g / m³. 2 Above and 180g / m 2Below. Grammage refers to the number of grams per square meter of surface area along the XY plane in a garment fabric F1. If the grammage of the second layer L2 is within the above range, then a good balance between thinness and strength will be achieved in the second layer L2. The grammage of the second layer L2 is adjusted during the stacking process of manufacturing the garment fabric F1 by the amount of fabric sheets stacked, i.e., the thickness of the sheets.

[0036] While the thickness of the second layer L2 is not particularly limited, it is preferably, for example, 0.20 mm or more and 0.80 mm or less. Accordingly, the softness and strength of the garment fabric F1 can be improved. In addition to the thickness of the sheet material described above, the thickness of the second layer L2 is also adjusted during the forming process of manufacturing the garment fabric F1 by factors such as the pressure conditions of the sheet material.

[0037] The bonding material binds the fibers together in the second layer L2. For the bonding material, a thermoplastic or thermosetting resin is used. Examples of resins include, in addition to thermoplastic synthetic resins such as polyester, shellac, rosin, dammar resin, polylactic acid, plant-derived polybutylene succinate, plant-derived polyethylene, and natural resins such as Kaneka Corporation's PHBH (registered trademark) (Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)). One of these bonding materials can be used alone, or in combination of two or more.

[0038] Additives other than adhesives include, for example, flame retardants, antioxidants, UV absorbers, agglomeration inhibitors, antibacterial agents, mildew inhibitors, waxes, and release agents.

[0039] The second layer L2 can also undergo pretreatment such as surface treatment on the first surface SF1 that is in contact with the first layer L1, or the second surface SF2 that is in contact with the third layer L3. Surface treatment can improve various physical properties such as abrasion resistance. Surface treatment is performed during the manufacturing process of the garment fabric F1.

[0040] While not specifically limited to surface treatments, examples include softening, waterproofing, wrinkle-resistant, and abrasion-resistant treatments. For these surface treatments, well-known fiber treatment agents can be used.

[0041] The third layer L3 is adhered to the side of the second layer L2, which is one of the first layer L1 and the second layer L2. A treatment agent that improves the heat retention of the garment fabric F1 is applied to the third layer L3. Thus, the third layer L3 provides heat retention in the garment fabric F1. If the third layer L3 is used on the outside of the garment, the heat retention during wear can be improved. Furthermore, the third layer L3 is not limited to being adhered to the side of the second layer L2; it can be adhered to at least one of the first layer L1 and the second layer L2.

[0042] Here, the term "thermal insulation" in this specification refers to the general term for heat insulation, airtightness, and heat storage properties. Specifically, thermal insulation refers to the property of suppressing the decrease in body temperature relative to the outside temperature or preventing heat loss from the body side to the outside when wearing clothing made from the fabric of this invention.

[0043] While the thickness of the third layer L3 is not particularly limited, it is preferably, for example, 0.01 mm or more and 1.00 mm or less. Accordingly, in the clothing fabric F1, softness and strength can be improved.

[0044] The substrate layer L3b becomes another surface of the clothing fabric F1. The substrate layer L3b is a sheet containing polyester fabrics, woven fabrics, and nonwoven fabrics. Accordingly, due to the superior strength of polyester, the thinness and strength of the clothing fabric F1 can be increased.

[0045] The substrate layer L3b is not limited to being made of polyester; it can be a sheet containing polyester and other resins, or a sheet made of resins other than polyester.

[0046] Adhesive layer L3a is located between substrate layer L3b and second layer L2. Adhesive layer L3a bonds the third layer L3 to the second layer L2, thereby ensuring the bond strength between them. Adhesive layer L3a contains an adhesive. The same material used for the adhesive as for adhesive layer L1a of the first layer L1 can be used.

[0047] Furthermore, the adhesive layer L3a is not a necessary structure, and the third layer L3 can also be composed solely of the substrate layer L3b. In this case, the third layer L3 and the second layer L2 are bonded together by the adhesive effect of the additives contained in the second layer L2.

[0048] An agent that improves thermal insulation is applied to the substrate layer L3b. The agent is not particularly limited as long as it improves thermal insulation; any known agent can be used. Specifically, examples of agents that form a resin film on the surface to improve sealing, and agents that utilize latent heat to mitigate the temperature drop of the human body side relative to the outside environment, are also included.

[0049] The treatment agent is applied to the third layer L3 during the manufacturing process of the garment fabric F1. Although details will be described later, the application of the treatment agent is performed on the surface of the substrate layer L3b, which is opposite to the adhesive layer L3a. Therefore, when the garment fabric F1 is processed into a garment, it is preferable to arrange the substrate layer L3b with the aforementioned surface facing outwards.

[0050] From the same perspective as coloring the first layer L1, the third layer L3 can also be colored. Coloring of the third layer L3 can be performed either during the fabric stage that forms the third layer L3, or during the manufacturing process of the garment fabric F1. In this embodiment, after applying a treatment agent to the third layer L3, coloring is performed from the surface of the substrate layer L3b. Therefore, since coloring is performed on the surface of the coating formed by the treatment agent, color rendering can be improved.

[0051] If the third layer L3 is used as the outer layer of the garment, the design of the garment can be enhanced through coloring. Coloring here includes not only coloring achieved with a single color, but also the formation of images such as text, patterns, paintings, and photographs through printing, etc. The methods described above for the first layer L1 can be applied to the coloring of the third layer L3.

[0052] The clothing fabric of the present invention may also have a different form than clothing fabric F1. Clothing fabrics F2 and F3, illustrated below, are examples of clothing fabrics of the present invention. Clothing fabrics F2 and F3 are clothing fabrics in which the configuration of the third layer L3 differs from that of clothing fabric F1. In the description of clothing fabrics F2 and F3, the same reference numerals are used for structures identical to those of clothing fabric F1, and repeated descriptions are omitted.

[0053] like Figure 2 As shown, the clothing fabric F2 has a multi-layer structure including a first layer L1, a second layer L2, and a third layer L3. In the clothing fabric F2, the substrate layer L3b of the third layer L, the adhesive layer L3a of the third layer L3, the substrate layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, and the second layer L2 are stacked sequentially from bottom to top. That is, in the clothing fabric F2, the third layer L3 is adhered to the side of the first layer L1, which is one of the first layer L1 and the second layer L2. This differs from the clothing fabric F1.

[0054] A treatment agent that improves the heat retention of the garment fabric F2 is applied to the third layer L3. Furthermore, the third layer L3 can be colored in the same manner as the garment fabric F1. When the garment fabric F2 is processed into a garment, from the viewpoint of the garment's heat retention, it is preferable to use the third layer L3 on the outer side of the garment.

[0055] like Figure 3 As shown, the clothing fabric F3 has a multi-layer structure including a first layer L1, a second layer L2, and two third layers L3. In the clothing fabric F3, the substrate layer L3b of the third layer L, the adhesive layer L3a of the third layer L3, the substrate layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, the second layer L2, the adhesive layer L3a of the third layer L3, and the substrate layer L3b of the third layer L3 are stacked sequentially from bottom to top. That is, in the clothing fabric F2, the third layer L3 is adhered to both the first layer L1 and the second layer L2, i.e., the first layer L1 side and the second layer L2 side. This differs from the clothing fabric F1.

[0056] The two third layers L3 are coated with a treatment agent that enhances the insulation properties of the garment fabric F2. Therefore, the garment fabric F3 has improved insulation properties compared to garment fabrics F1 and F2. By changing the configuration and quantity of the third layers L3 relative to the first layer L1 and the second layer L2, the insulation properties can be adjusted.

[0057] Alternatively, one or both of the two third layers L3 can be colored in the same way as the fabric F1 used for clothing.

[0058] 2. Manufacturing methods for clothing fabrics The method for manufacturing clothing fabric F1 described in this embodiment is an example of the method for manufacturing clothing fabric according to the present invention. The method for manufacturing clothing fabric F1 is an example and is not limited to the following structure and order. The method for manufacturing clothing fabric F1 can also be applied to the manufacturing of clothing fabrics F2 and F3.

[0059] like Figure 4 As shown, the manufacturing method of clothing fabric F1 includes a raw material supply process S1, a fiber unwinding process S2, a mixing process S3, a stacking process S4, a forming process S5, a bonding process S6, and a coating process S7. In the manufacturing method of clothing fabric F1, clothing fabric F1 is manufactured by passing through each process in the above order from the upstream raw material supply process S1 to the downstream coating process S7.

[0060] A specific example of the method for manufacturing clothing fabric F1 will be described together with the fabric manufacturing apparatus 1 used to manufacture clothing fabric F1. The fabric manufacturing apparatus 1 of this embodiment is an example and is not limited to the following structure. In the fabric manufacturing apparatus 1, the destination of the conveying direction of raw materials, fabric, sheet materials and semi-finished products is sometimes referred to as downstream, and the side that flows back along the conveying direction is referred to as upstream.

[0061] like Figure 5As shown, the fabric manufacturing apparatus 1 includes, from upstream to downstream, a supply unit 5, a shredding unit 10, a fiber unwinding unit 30, a mixing unit 60, a stacking unit 100, a sheet conveying unit 70, a forming unit 150, a bonding unit 73, and a processing unit 170. Furthermore, the fabric manufacturing apparatus 1 also includes a control unit 28 that comprehensively controls the operation of each of the above-mentioned structures.

[0062] The raw material supply process S1 is performed by the supply unit 5. The supply unit 5 supplies raw material C to the coarse crushing unit 10. The supply unit 5 is equipped with, for example, an automatic feeding mechanism (not shown), and continuously and automatically feeds raw material C into the coarse crushing unit 10. Raw material C is used clothing or other fabric.

[0063] The coarse crushing section 10 cuts the raw material C supplied from the supply section 5 into fragments in an atmosphere such as air. The coarse crushing section 10 is a crusher or cutting and grinding machine with coarse crushing blades 11. The raw material C is cut by the coarse crushing blades 11 to become fragments of raw material C. The planar shape of the fragments is, for example, a square of a few millimeters or an irregular shape. The fragments are collected in the metering supply section 50. Alternatively, the raw material C may be pre-crushed before being fed into the supply section 5.

[0064] The quantitative supply unit 50 measures the fragments of raw material C and supplies them quantitatively to the hopper 12. The quantitative supply unit 50 is, for example, a vibrating feeder. The fragments of raw material C supplied to the hopper 12 are conveyed in the pipe 20 and reach the inlet 31 of the defiberization unit 30. Then, they enter the defiberization process S2.

[0065] The fiber-debonding process S2 is performed by the fiber-debonding unit 30. The fiber-debonding unit 30 debonds the fine pieces originating from the fabric material C in a dry manner, thereby generating and extracting the fibers contained in the fabric material C. The fiber-debonding unit 30 includes an inlet 31, an outlet 32, a stator 33, a rotor 34, and an airflow generating mechanism (not shown). Fragments of the fabric material C are introduced into the interior of the fiber-debonding unit 30 through the inlet 31 by the airflow generated by the airflow generating mechanism.

[0066] The stator 33 and rotor 34 are disposed inside the defiberization section 30. The stator 33 has a generally cylindrical inner surface. The rotor 34 rotates along the inner surface of the stator 33. Fragments of raw material C are trapped between the stator 33 and the rotor 34 and defiberized by the shear force generated between them.

[0067] The fibers generated by the defiberization section 30 are discharged from the outlet 32 ​​into the pipe 40. The pipe 40 is connected to the interior of the defiberization section 30 and the interior of the stacking section 100. The fibers are transported from the defiberization section 30 to the stacking section 100 by the airflow generated by the airflow generating mechanism. A mixing section 60 is provided on the pipe 40 between the defiberization section 30 and the stacking section 100.

[0068] Although the illustration is omitted, the fabric manufacturing apparatus 1 may also include a sorting mechanism between the defibering section 30 and the mixing section 60 to remove impurities and other contaminants contained in the defibered fibers. Known devices such as sieves can be cited as examples of the sorting mechanism. With the sorting mechanism, the impurity content can be reduced, and fibers with higher purity can be used as the material for the second layer L2. Then, the process proceeds to the mixing step S3.

[0069] The mixing process S3 is performed by the mixing unit 60. The mixing unit 60 mixes the fibers obtained in the fiber-debonding process S2 with additives such as binding materials to generate a mixture. The mixing unit 60 includes hoppers 13 and 14, supply pipes 61 and 62, and valves 65 and 66. In the mixing unit 60, the fibers and binding materials are mixed in air to form a mixture. As mentioned above, the mixture preferably does not contain color materials. "Does not contain color materials" here means that color materials such as pigments are intentionally not added to the mixture. That is, the mixture may contain color materials such as dyes that have penetrated into the fibers, or color materials that have been accidentally mixed in.

[0070] Hopper 13 is connected to the interior of pipe 40 via supply pipe 61. A valve 65 is disposed between hopper 13 and pipe 40 in supply pipe 61. Hopper 13 supplies the binding material into pipe 40. Valve 65 regulates the mass of the binding material supplied from hopper 13 to pipe 40. Thus, the mixing ratio of fiber to binding material is adjusted. The binder can be supplied in powder or particle form, or it can be supplied melted.

[0071] Hopper 14 is connected to the interior of pipe 40 via supply pipe 62. A valve 66 is disposed between hopper 14 and pipe 40 in supply pipe 62. Hopper 14 supplies additives other than binder into pipe 40. Valve 66 regulates the mass of additives other than binder supplied from hopper 14 to pipe 40. Thus, the mixing ratio of the additives with respect to fibers and binder is adjusted. Alternatively, additives other than binder can be pre-mixed with binder and supplied from hopper 13. Furthermore, if no additives other than binder are added to the mixture, hopper 14, supply pipe 62, and valve 66 can be omitted.

[0072] Fibers and binding materials are mixed while being conveyed to the stacking section 100 within the pipe 40 to form a mixture. To promote the formation of the mixture in the pipe 40 and improve its conveyability, a blower or similar device that generates airflow may be installed on the pipe 40. The mixture is introduced from the pipe 40 to the stacking section 100 via the connecting part 42. It then proceeds to the stacking process S4.

[0073] The stacking process S4 is performed by the stacking section 100. The stacking section 100 stacks the mixture in the air onto a breathable fabric N1, thereby generating a sheet W that becomes the second layer L2. Fabric N1 becomes the first layer L1 of the garment fabric F1. In other words, the sheet W is formed by stacking a mixture containing de-spun fibers and additives in the air onto fabric N1, which becomes the first layer L1. This facilitates the formation of the sheet W and changes in its weight.

[0074] The stacking section 100 includes a roller section 101, a cover section 102 for housing the roller section 101, and a fabric supply section 71 for supplying fabric N1. The stacking section 100 draws a mixture from the tube 40 into the interior of the roller section 101. Then, the mixture is stacked on the fabric N1 supplied from the fabric supply section 71 in a dry manner.

[0075] A sheet conveying section 70 is disposed below the stacking section 100. The sheet conveying section 70 includes a mesh belt 122 and a suction mechanism 110. The suction mechanism 110 is disposed opposite the roller section 101 in the direction along the Z-axis, across the mesh belt 122.

[0076] The drum section 101 includes a blade member 101a that is driven to rotate by a motor (not shown), and a generally cylindrical sieve section 101b that is configured to primarily cover the underside of the blade member 101a. The blade member 101a unravels intertwined fibers as it rotates. The sieve section 101b allows particles such as fibers and mixtures, which are smaller than the mesh size of the sieve, to pass through from the inside to the outside. As a result, the intertwined fibers in the mixture are untangled in the drum section 101 and dispersed into the air within the housing section 102.

[0077] The fabric supply unit 71 continuously feeds the roll of fabric N1 onto the mesh belt 122. At this time, the adhesive layer L1a of the fabric N1 is positioned with its upward-facing surface. Thus, the adhesive layer L1a is in contact with the sheet material W. When the release liner is adhered to the adhesive layer L1a of the fabric N1, the fabric supply unit 71 may also include a mechanism for separating the cellophane from the fabric N1. Alternatively, pre-dyed fabric may be used as the fabric N1.

[0078] The fiber-containing mixture is dispersed from the inside of the sieve section 101b into the air inside the cover section 102. Furthermore, the fiber-containing mixture randomly accumulates above the fabric N1 being conveyed on the mesh belt 122. Therefore, in the fabric sheet W, the fibers become difficult to orient in a specific direction.

[0079] The sieve section 101b may not have the function of screening larger fibers in the mixture. That is, the roller section 101 may also untangle the fibers of the mixture and release the entire mixture into the interior of the cover section 102. The mixture dispersed in the air inside the cover section 102 is accumulated on the surface above the fabric N1 by gravity and the suction force of the suction mechanism 110.

[0080] The weight per unit area of ​​fabric F1 for clothing is adjusted by fabric N1, fabric N3 (described later), and sheet W. The weight per unit area of ​​sheet W is adjusted by the rotation number of blade component 101a, the amount of mixture supplied to stacking section 100 per unit time, and the conveying speed of fabric N1 achieved by mesh belt 122.

[0081] Here, in the stacking process S4, the thickness of the second layer L2 of the garment fabric F1 can also be adjusted by changing the thickness of the sheet W. This changes the amount of air contained in the second layer L2, thus altering its insulation properties. Therefore, in addition to the third layer L3, the insulation properties of the second layer L2 can also be adjusted, further facilitating the adjustment of the insulation properties of the garment fabric F1. The thickness of the sheet W can be adjusted using factors such as the weight per unit area of ​​the sheet W or the pressure applied during the forming process S5.

[0082] The mixing ratio of fibers and additives is not particularly limited and can be appropriately adjusted depending on the type of additive. For example, in fabric sheet W, the mass ratio of fibers to binding materials is preferably set in the range of fiber:binding material = 9:1 to 5:5. Accordingly, a balance of various physical properties of the garment fabric F1 can be achieved.

[0083] The sheet conveying unit 70 includes a mesh belt 122 and a suction mechanism 110. The sheet conveying unit 70 promotes the accumulation of the mixture onto the fabric N1 by the suction mechanism 110. In addition, the sheet conveying unit 70 conveys the sheet W formed from the mixture downstream by the rotation of the mesh belt 122.

[0084] A suction mechanism 110 is disposed below the roller section 101. The suction mechanism 110 draws air from inside the cover section 102 through multiple holes in the mesh belt 122 and through the breathable fabric N1. As a result, the mixture released to the outside of the roller section 101, along with the air, is drawn downwards and accumulates on the surface above the fabric N1. A known suction device such as a blower is used for the suction mechanism 110.

[0085] The mesh belt 122 has multiple holes that allow air to pass through while making it difficult for fibers or binding materials contained in the mixture to pass through. The mesh belt 122 is a seamless belt and is supported by four support rollers 121.

[0086] The mesh belt 122 moves downstream by the rotation of the mounting roller 121, causing its upper surface to face downwards. In other words, the mesh belt 122... Figure 4 The conveyor belt 122 rotates clockwise. The conveyor belt 122 rotates using the mounting roller 121, causing the mixture to continuously accumulate on the fabric N1 to form a sheet W. The sheet W contains a relatively large amount of air, thus softly expanding. The sheet W, together with the fabric N1, is conveyed downstream along with the conveyor belt 122.

[0087] Alternatively, a humidifier 130 can be installed downstream of the stacking section 100 to humidify the sheet W by spraying water in the form of mist. This can suppress the scattering of fibers or binding materials contained in the sheet W. Furthermore, the water used for humidification can contain water-soluble additives, and the sheet W, which becomes the second layer L2, can be surface-treated in parallel with humidification.

[0088] The sheet material W and fabric N1 are conveyed downstream via the mesh belt 122 and peeled off from the mesh belt 122 before being introduced into the buffer roller 141. The buffer roller 141 is configured to ensure the processing time of the downstream forming process S5. Specifically, since the forming process S5 is a batch process, the buffer roller 141 is moved up and down relative to the sheet material W and fabric N1 that are continuously supplied from the stacking section 100, thereby ensuring the processing time of the forming process S5. The sheet material W and fabric N1 are conveyed downstream via the buffer roller 141 and then enter the forming process S5.

[0089] The forming process S5 is performed by the forming unit 150. The forming unit 150 overlaps the fabric N1 and sheet W of the first layer L1, and heats and presses them to form the material. The forming unit 150 is a heated stamping device and includes an upper substrate 152 and a lower substrate 151. The upper substrate 152 and the lower substrate 151 sandwich the sheet W and fabric N1 between them and press them, and heat the sheet W and fabric N1 by means of a built-in heater. Alternatively, in the forming process S5, the forming process S5 can also be performed continuously using heating rollers.

[0090] The sheet W is compressed from top to bottom under pressure to increase its density, and the bonding material is melted by heating to wet and spread between the fibers. When heating ends and the bonding material solidifies in this state, the fibers are bonded together by the bonding material. Furthermore, the fabric N1 is bonded to the fabric W, thus fabric N1 becomes the first layer L1, and the sheet W becomes the second layer L2.

[0091] The pressure and heating conditions in the forming section 150 are appropriately adjusted according to the desired density of the garment fabric F1, the melting point of the bonding material, or the curing temperature. Although not particularly limited, for example, the pressure conditions are set to a pressure of 0.01 MPa or higher, and the heating conditions are set to a temperature of 90°C or higher.

[0092] In the forming process S5, the thickness of the second layer L2 can be adjusted by changing the pressure applied to the forming section 150. As a result, the density of the voids in the second layer L2 changes, thereby allowing adjustment of the thermal insulation properties of the second layer L2.

[0093] The first layer L1 and the second layer L2 are integrally formed from the fabric N1 and the sheet W via the forming section 150. Then, the bonding process S6 is performed.

[0094] In the bonding process S6, fabric N3, which becomes a third layer L3, is bonded to at least one of the first layer L1 and the second layer L2. In the garment fabric F1, the third layer L3 is bonded to the second layer L2. Therefore, in the bonding process S6, fabric N3, which becomes a third layer L3, is bonded to the surface above the second layer L2. Fabric N3 includes an adhesive layer L3a (not shown) and a substrate layer L3b. Fabric N3 may also be pre-dyed in the same way as fabric N1.

[0095] The pasting process S6 is performed by the fabric supply unit 72 and the pasting unit 73. The fabric supply unit 72 continuously feeds the roll of fabric N3 upwards onto the second layer L2. At this time, the adhesive layer L3a of the fabric N3 is positioned downwards, so that the adhesive layer L3a abuts against the second layer L2. When the release paper is pasted onto the adhesive layer L3a of the fabric N3, the fabric supply unit 72 may also be equipped with a separation mechanism to separate the release paper from the fabric N3.

[0096] The adhesive part 73 adheres the upper surface of the second layer L2 to the adhesive layer L3a of the fabric N3. The adhesive part 73 is a pair of pressing rollers that press the first layer L1 and the second layer L2 to the fabric N3 from the top and bottom. This forms the third layer L3 of the garment fabric F1. Alternatively, the adhesive part 73 can be equipped with a heating mechanism to press and adhere the fabric N3 to the second layer L2.

[0097] Here, when manufacturing the clothing fabric F2 described above, fabric N3 is pasted from below the first layer L1. Furthermore, when manufacturing the clothing fabric F3 described above, fabric N3 is pasted to both the bottom of the first layer L1 and the top of the second layer L2. Then, the coating process S7 is initiated.

[0098] The coating process S7 is performed by the processing unit 170. The processing unit 170 applies a treatment agent that improves the heat retention of the third layer L3. The processing unit 170 is, for example, a spraying device, which sprays out a solution of the treatment agent in the form of a mist and coats it onto the third layer L3. The processing unit 170 is not limited to a spraying method, and can also be a known method such as dripping, inkjet, or roller coating.

[0099] A portion of the treatment agent solution coated on the third layer L3 penetrates into the interior of the substrate layer L3b, while the remainder remains on the surface of the substrate layer L3b. Subsequently, the volatile components of the treatment agent solution evaporate, thereby forming a coating layer of treatment agent on both the surface and interior of the substrate layer L3b. The evaporation of these volatile components can be achieved through air drying or evaporation by an air supply mechanism or heating mechanism (not shown).

[0100] In coating step S7, the treatment agent is applied to the third layer L3. The treatment agent can be a resin solution or emulsion that forms a resin film, or a slurry or powder containing latent heat storage materials. The coating method is not limited to spraying; it can be changed to roller coating, inkjet coating, etc., depending on the properties of the treatment agent.

[0101] Examples of treatment agents for forming the resin coating include emulsions such as polyurethane resin or acrylic resin, thermosetting or electron beam curing monomers, and their curing agents. Commercially available products can be used for these treatment agents. Accordingly, the resin coating formed from the treatment agent improves the airtightness of the clothing fabric F1, thereby inhibiting the intrusion of cold air from the outside and the loss of heat from the body side. Therefore, the heat insulation properties of the third layer L3 can be further improved.

[0102] Examples of treatment agents that utilize latent heat include those containing known latent heat storage materials such as fatty acid compounds and paraffin. For latent heat storage materials, commercially available products such as Riken Kogyo Co., Ltd.'s PCM series of heat-storing paraffins and Sumitomo Chemical Co., Ltd.'s Conforma (registered trademark) can be used. Accordingly, the heat accumulated in the coating layer is released, thereby suppressing the temperature drop on the human body side. Therefore, the heat insulation properties of the third layer L3 can be further improved.

[0103] The surface of the third layer L3, i.e., the coating layer of the substrate layer L3b, can also be colored using pigments or inks. By coloring the surface of the coating layer, the color development can be improved compared to the case where the fabric N3 is pre-colored. The coloring of the third layer L3 is not limited to coloring the entire surface of the third layer L3 with a single color; it can also be used to create images such as text, patterns, conversations, and photographs.

[0104] The coloring apparatus for applying color to the third layer L3 is not particularly limited, and known apparatuses such as ink ejection apparatuses and ink coating apparatuses can be cited as examples. When producing garment fabric F1 in small quantities with multiple varieties, an ink ejection apparatus including an inkjet head is preferred. Furthermore, as a pre-treatment stage before coloring, a pretreatment can be performed on the coating layer of the third layer L3. For example, the pretreatment can improve the abrasion resistance and wash fastness of the garment processed from the garment fabric F1.

[0105] A cutting section (not shown) may also be provided downstream of the processing unit 170 to trim the shape of both ends of the garment fabric F1 along the Y-axis. Specifically, the cutting section has a longitudinal blade. The longitudinal blade cuts the strip of garment fabric F1 along the conveying direction. Thus, the edges of both ends of the garment fabric F1 are neatly trimmed. The cutting section may also be positioned between the pasting unit 73 and the processing unit 170.

[0106] After being coated in the coating process S7, the garment fabric F1 is wound into a roll shape by a winding mechanism (not shown). The garment fabric F1 is thus manufactured in this manner.

[0107] According to this embodiment, the following effects can be obtained.

[0108] The heat retention of the garment fabric F1 to be manufactured can be adjusted. Specifically, by attaching fabric N3, which becomes a third layer L3, to the second layer L2, and applying a treatment agent to the third layer L3, the heat retention is adjusted to be more effective compared to the case without the treatment agent. Furthermore, in the garment fabric F3, by attaching fabric N3, which becomes a third layer L3, to both the first layer L1 and the second layer L2, and applying a treatment agent to both third layers L3, the heat retention can be further improved. Therefore, depending on whether the third layer L3 is attached to one of the first layer L1 and the second layer L2, or to both of the first layer L1 and the second layer L2, the heat retention changes. Thus, a method for manufacturing garment fabric that adjusts its heat retention can be provided.

[0109] The insulation properties of clothing fabrics F1, F2, and F3 can be adjusted. Specifically, by attaching fabric N3, which becomes a third layer L3, to the second layer L2 and applying a treatment agent to the third layer L3, the insulation properties are adjusted to improve compared to the case without the treatment agent. Furthermore, in clothing fabric F3, by attaching fabric N3, which becomes a third layer L3, to both the first layer L1 and the second layer L2, and applying a treatment agent to both third layers L3, the insulation properties can be further improved. Therefore, the insulation properties change depending on whether the third layer L3 is attached to one of the first layer L1 and the second layer L2, or to both of the first layer L1 and the second layer L2. Thus, clothing fabrics F1, F2, and F3 with adjusted insulation properties can be provided.

[0110] Symbol Explanation C… as raw material for fabric; F1, F2, F3… fabric for clothing; L1… first layer; L2… second layer; L3… third layer; N1… fabric that becomes the first layer; N3… fabric that becomes the third layer; S2… desiccation process; S3… mixing process; S4… stacking process; S5… forming process; S6… bonding process; S7… coating process; W… sheet material.

Claims

1. A method for manufacturing a fabric for clothing, characterized in that, have: The defiberization process involves dry defiberizing the fabric to produce fibers. A mixing process involves adding additives to the fibers obtained in the defiberization process to generate a mixture. The stacking process involves stacking the mixture in the air onto a breathable fabric that forms the first layer, in order to create a sheet that forms the second layer. The forming process involves overlapping the first layer of fabric and the sheet material, and then heating and pressing them to form the shape. The pasting process involves pasting a third layer of fabric onto at least one of the first layer and the second layer. In the coating process, a treatment agent that improves the thermal insulation is applied to the third layer.

2. The method for manufacturing clothing fabric as described in claim 1, wherein, In the coating process, the latent heat storage material is coated as the treatment agent.

3. The method for manufacturing clothing fabric as described in claim 1, wherein, In the coating process, a resin film is formed on the third layer by the treatment agent.

4. The method for manufacturing clothing fabric as described in claim 1, wherein, In the stacking process, the thickness of the second layer is adjusted by changing the thickness of the sheet material.

5. The method for manufacturing clothing fabric as described in claim 1, wherein, In the forming process, the thickness of the second layer is adjusted by changing the pressure applied during pressurization.

6. A fabric for clothing, characterized in that, include: The first layer is breathable; The second layer consists of a sheet of material formed by stacking a mixture of fibers and additives in the air, the fibers being obtained by dry-splitting the fabric. The third layer is adhered to at least one of the first and second layers and is coated with a treatment agent that improves moisture retention.

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