Clothing member and method for manufacturing clothing member

Abstract

A member for clothing, which is a member for clothing formed by three-dimensionally stacking resin fibers on a base material using a melt-blowing method under normal pressure conditions, has a configuration in which resin fibers are three-dimensionally stacked in the thickness direction.

Description

[0001] This application is a divisional application of the application filed on January 27, 2022, with application number "202280011961.5" and invention title "Clothing Component and Method for Manufacturing Clothing Component". Technical Field

[0002] This disclosure relates to a fabric component and a method for manufacturing the fabric component. Background Technology

[0003] Various methods for manufacturing nonwoven fabrics or nonwoven structures are known, and these nonwoven fabrics or nonwoven structures are suitable for use as clothing components. As methods for manufacturing nonwoven fabrics or nonwoven structures, the techniques described in Patent Documents 1 to 6 are known, for example. Patent Document 1 describes a method for manufacturing nonwoven fabrics for shoes, clothing, and sporting goods, in which fibers are supplied to a breathable substrate, and a pressure difference is applied to the breathable portion of the substrate. As an example of the manufacturing method, a meltblown method is described. Patent Document 2 describes a method for manufacturing a molded body, in which hot-melt adhesive composite ultrafine fibers with an average fiber diameter of less than 10 μm are sprayed onto a breathable molded substrate in a three-dimensional manner using a meltblown method.

[0004] Patent document 3 describes a device for spraying multiple fibers from a meltblown apparatus onto a three-dimensional model connected to a support, incorporating a collection shaft to remove excess fibers. This device enables the manufacture of shoes, wetsuits, masks, headscarves, hats, women's underwear, sports bras, knee pads, and wristbands. Patent document 4 describes a cushioning substrate composed of a nonwoven fiber assembly containing heat-bonding fibers, where the bonding points of the heat-bonding fibers within the assembly are distributed substantially uniformly. This cushioning substrate can be applied to bra cups or insole substrates, etc.

[0005] Patent Document 5 describes an apparatus for forming a nonwoven fabric by charging a raw material liquid and depositing nanofibers into stacking units that achieve a three-dimensional shape corresponding to the desired shape of an unbonded cylindrical body. This apparatus can be used to manufacture swimsuits, diapers, wetsuits, bras, hats, gloves, socks, abdominal binders, clothing, or underwear. Patent Document 6 describes a manufacturing method for covering the surface of a core material of a desired shape by spraying self-adhesive fibers onto it, and then removing the core material to manufacture a wearable garment. The fiber raw material can be materials suitable for nonwoven fabric manufacturing methods such as thermal bonding, spunbonding, or meltblowing.

[0006] [Existing Technical Documents] [Patent Literature] Patent Document 1: Japanese Patent Application Publication No. 2018-96021 Patent Document 2: Japanese Patent Application Publication No. 4-65568 Patent Document 3: Japanese Patent Application Publication No. 2012-31555 Patent Document 4: International Publication No. 2009 / 028564 Patent Document 5: Japanese Patent Application Publication No. 2009-293168 Patent document 6: Japanese Patent Application Publication No. 5-186949. Summary of the Invention

[0007] (The problem the invention aims to solve) Previously, clothing components made from molded bodies using polyurethane or similar materials, or from sewn fabrics such as nonwoven fabrics, were known. It was believed that clothing components made from the aforementioned nonwoven fabrics or nonwoven structures had superior breathability compared to molded bodies using polyurethane or similar materials. Furthermore, compared to clothing components sewn from nonwoven fabrics, clothing components made from nonwoven fabrics or nonwoven structures eliminated seam marks (sewing lines, etc.), thus exhibiting superior smoothness and other aesthetic qualities. However, in nonwoven fabrics or nonwoven structures obtained using conventional meltblown methods, it was difficult to adjust various characteristics of the component, such as breathability at specific locations, smoothness, thickness, and density, to the desired values. Especially when nonwoven structures are used for clothing components, a technique for adjusting the component's properties is needed.

[0008] This disclosure describes a garment component with adjustable properties at specific locations and a method for manufacturing the garment component.

[0009] (Methods used to solve problems) One aspect of this disclosure relates to a fabric component having a structure formed by three-dimensionally stacking resin fibers in the thickness direction.

[0010] According to this fabric component, by appropriately adjusting the density or height of the resin fiber packing in the thickness direction and / or the surface direction, the density or thickness and other properties of the fabric component can be adjusted. In particular, the properties at specific locations of the fabric component can be adjusted.

[0011] The resin fibers can also be stacked in a manner that maintains the gaps between the resin fibers. By forming a state that maintains the gaps (spaces) between the resin fibers, the breathability and / or bulkiness of the clothing components can be ensured.

[0012] In clothing components, the average fiber diameter of the resin fibers can be less than 0.4 mm and more than 10 μm. By reducing (refining) the average fiber diameter of the resin fibers, the hand feel and smoothness can be improved.

[0013] Clothing components can also have a breathability of 0.4 kPa·s / m or less. Increased breathability makes them more suitable for use as clothing components. Furthermore, breathability is measured, for example, by the KES method (measured using a KES-F8 breathability testing machine). When expressed in units of "kPa·s / m", the lower the value, the higher the breathability.

[0014] The fabric component may also have a shape that bulges out toward the first side in a manner that follows a part of the wearer's body, and the smoothness of the first side is higher than that of the opposite side, the second side. For example, when the first side is located on the outside of the fabric, the appearance can be improved.

[0015] In clothing components, the thickness can vary in the planar direction due to differences in the amount of resin fibers deposited. Because the thickness of the clothing component varies in the planar direction, the cushioning and other properties in different parts of the planar direction can be freely adjusted. In addition, adjustments can be made to minimize the thickness in specific locations in the planar direction.

[0016] Clothing components may also have multiple resin fiber layers that differ in at least one of the following: type of resin material, diameter of resin fibers, and density of resin fibers. By having multiple resin fiber layers, the functionality of the clothing component as a clothing component can be further improved.

[0017] In clothing components, multiple resin fiber layers may also include a first layer and a second layer, with the second layer being thicker than the first layer. In this case, the second layer ensures bulkiness.

[0018] In a fabric component, the multiple resin fiber layers may further include a third layer, with a second layer disposed between the first and third layers. The thickness of the second layer is greater than either the thickness of the first or the thickness of the third layer. In this case, either the first or the third layer possesses characteristics that take into account the impact on appearance or the impact due to external forces. On the other hand, the second layer ensures the bulkiness of the fabric component. The thickness of the second layer may also be greater than either the thickness of the first or the thickness of the third layer (i.e., both).

[0019] In the fabric component, the density of the resin fibers in the second layer can be lower than either the density of the resin fibers in the first layer or the density of the resin fibers in the third layer. This second layer ensures the bulkiness of the fabric component and allows for a relatively high fiber density in the first and third layers, thereby improving surface smoothness and appearance. Additionally, it also improves the wash durability of the fabric during washing.

[0020] As another aspect of this disclosure, a method for manufacturing a fabric component is provided, using a melt-blowing method and controlling the position of the substrate to three-dimensionally deposit resin fibers on the substrate under normal pressure.

[0021] According to the manufacturing method of this fabric component, by appropriately adjusting the density or height of the resin fiber stacking in the thickness direction and / or the surface direction, the density or thickness and other characteristics of the fabric component can be adjusted. Furthermore, since suction or similar processes involving applied pressure are not performed, it is easy to manufacture fabric components with complex shapes using substrates with complex shapes.

[0022] In a method for manufacturing a fabric component, the surface of a substrate may have a concave portion, and resin fibers can be sprayed onto this concave portion to deposit the resin fibers. By spraying resin fibers onto the concave portion of the substrate, moldability can be improved even without applying a pressure differential or removing excess fibers. Furthermore, a bulging surface is formed corresponding to the concave portion. When the surface of the fabric component is located on the outer side of the fabric, the appearance can be improved.

[0023] In the manufacturing method of a fabric component, the thickness of the fabric component in the planar direction can be changed by altering at least one of the following: resin ejection pressure, resin fiber spraying time, airflow, and distance from the resin fiber nozzle to the substrate. By changing the thickness of the fabric component in the planar direction, the cushioning properties and other characteristics in each part of the planar direction can be freely adjusted. Furthermore, adjustments can be made at specific locations in the planar direction to minimize the thickness.

[0024] In a method for manufacturing clothing components, the characteristics of the clothing component in the thickness direction can be altered by changing at least one of the following in the vertical direction of the substrate: the type of resin material, the resin ejection pressure, the resin fiber spraying time, the air volume, and the distance from the resin fiber nozzle to the substrate. By altering the characteristics of the clothing component in the thickness direction, it is possible to manufacture, for example, clothing components having multiple resin fiber layers. Therefore, the functionality of the clothing component can be further improved.

[0025] In the manufacturing method of clothing components, multiple resin fiber layers can be formed by varying at least one of the types of resin materials, the diameter of resin fibers, and the density of resin fibers. By having multiple resin fiber layers in the clothing component, its functionality as a clothing component can be further improved.

[0026] The manufacturing method for clothing components may include: a step of preparing a substrate produced by a three-dimensional lamination molding method; a step of holding the substrate in a substrate holder of a substrate position control device; and a step of depositing resin fibers onto the substrate by melt-blowing while moving the holder. When the substrate is produced by a three-dimensional lamination molding method, there are fewer restrictions on the shape or structure of the substrate, and any three-dimensional shape can be achieved. For example, the portion held in the substrate holder (the held portion, i.e., the base), the portion where resin fibers are deposited (the deposited portion), and the connecting portions between them can be freely manufactured. Therefore, the degree of freedom in the shape of the clothing component is also high. Furthermore, by changing the position and orientation of the substrate holder using the substrate position control device, it is easy to change the type or amount of resin fibers deposited on each part of the substrate.

[0027] (Invention Effects) According to this disclosure, the properties of a fabric component at a specific location can be adjusted. Attached Figure Description

[0028] [ Figure 1 ] Figure 1 This is a perspective view showing a fabric component according to an embodiment of the present disclosure.

[0029] [ Figure 2 ] Figure 2 (a) is a cross-sectional view of a bra cup as an example of a fabric component. Figure 2 (b) to make Figure 2 (a) is a cross-sectional view of the bra, shown as an enlarged portion of the cups.

[0030] [ Figure 3 ] Figure 3 A diagram showing a manufacturing apparatus for fabric components.

[0031] [ Figure 4 ] Figure 4 (a) A diagram illustrating an example of a state in which resin fibers are sprayed onto a substrate to form a deposit. Figure 4 (b) A diagram illustrating the state of resin fibers being sprayed onto a substrate to accumulate in another example.

[0032] [ Figure 5 ] Figure 5 This is a cross-sectional photograph of a fabric component according to one embodiment.

[0033] [ Figure 6 ] Figure 6 (a) is a photograph of the surface of the bra cup involved in the embodiment. Figure 6 (b) is Figure 6 (a) A photograph of the inside of the bra cups.

[0034] [ Figure 7 ] Figure 7 (a) An electron microscope image of the surface of the bra cup involved in the embodiment. Figure 7 (b) is Figure 7 (a) Electron microscope photograph of the inner surface of the bra cup. Detailed Implementation

[0035] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. Furthermore, the same symbols are used to denote the same elements in the drawings, and repeated descriptions are omitted.

[0036] Reference Figure 1 and Figure 2 The following describes the clothing component according to this embodiment. The clothing component 200 is a component used to form the various parts of the clothing. There are no particular limitations on the type of clothing; examples include: bras, camisole-style women's underwear, shorts, girdles, men's briefs, trunks, inner shirts, and other close-fitting garments (underwear). In addition, the clothing can also be tops such as long-sleeved or short-sleeved shirts, or outerwear such as jackets. The clothing can also be bottoms such as pantyhose, leggings, spas, tights, sports tights, swimwear, leotards, bodysuits, or trousers. The clothing component has a specific thickness. The fabric components constitute at least a part of the aforementioned fabric. For example, they may be bra cups or padding covering the wearer's breasts, padding covering the joints of the wearer's body (knee pads or shoulder pads), or components covering other parts of the wearer's body (bra straps, or buttock pads for bottoms). The fabric components may also constitute the entirety of the aforementioned fabric. The fabric components may be, for example, half-top bras or shorts.

[0037] The term "the entire garment" refers to both the fabric itself and its general structure. This includes components made of materials such as metal or plastic. Figure 1 In the case of the adjusting buckle 105 of the shoulder strap 104 shown or the hook 106 provided at the end of the shoulder strap, or decorative parts, the fabric component may also be the entire main body except for these structural or decorative parts.

[0038] The following description addresses the case where the fabric component 200 is the cup of the bra 100. For example... Figure 1 and Figure 2As shown, the fabric component 200 is a nonwoven structure comprising resin fibers fused together. The fabric component 200 is a nonwoven structure manufactured, for example, by a meltblown process (i.e., a meltblown nonwoven structure). The fabric component 200 has a structure formed by three-dimensionally stacking resin fibers in the thickness direction. The fabric component 200 is joined to other components such as the base 103 and shoulder straps 104 by sewing or bonding, etc., to assemble it into a bra 100. Like the cups (or pads) of the bra 100, when a pair of components are arranged symmetrically, such as... Figure 1 The cups shown can be manufactured separately, or the left and right cups (or pads) can be joined together and manufactured as a single piece. The fabric component 200 has a three-dimensional shape (cup shape) suitable for covering the wearer's chest. Additionally, as... Figure 1 As shown, this disclosure can also be applied to a generally planar fabric component 300 that serves as the strap of a bra 100.

[0039] The fabric component 200 can be any component having a structure formed by three-dimensionally depositing resin fibers in the thickness direction. That is, the fabric component 200 can be any three-dimensional molded article. Furthermore, shoes are not included in the fabric in this specification. Therefore, the midsole of the shoe is not included in the fabric component.

[0040] Clothing component 200 is fabricated on substrate 50 (see reference) using a melt-blown method. Figure 3 This fabric component 200 is manufactured by three-dimensionally stacking resin fibers F under normal pressure conditions (e.g., atmospheric pressure conditions) (details to be described later). Through this manufacturing method, the resin fibers in the fabric component 200 are stacked in a state that maintains the gaps (spaces) between the resin fibers. In this specification, "gap" can be defined as, for example, a space with an inter-fiber distance of approximately 1 to 100 times the diameter of the resin fiber F, or a space with a porosity of 5% to 60%. In conventional meltblowing methods, resin fibers are fixed to the substrate by applying suction pressure (pressure difference) from one side of the substrate. However, in this embodiment, where the type of resin material or spraying conditions are adjusted, and the meltblowing method is performed under normal pressure conditions, the apparatus can be simplified since no suction pressure is applied. Furthermore, when suction pressure is applied, it is difficult to use substrates with complex shapes because a certain degree of uniform suction pressure needs to be applied at all locations. However, in this embodiment where the meltblowing method is performed under normal pressure conditions, substrates with complex shapes can be used.

[0041] The fabric component 200 of this embodiment has an air permeability of, for example, 0.4 kPa·s / m or less. The fabric component 200 may have an air permeability of 0.35 kPa·s / m or less, 0.3 kPa·s / m or less, or 0.25 kPa·s / m or less. Air permeability can be measured, for example, by the KES method (measured using a KES-F8 air permeability testing machine). The lower the air resistance value expressed in "kPa·s / m", the higher the air permeability. Air permeability can be measured using JIS L1096 Air Permeability A Method (Frazir type test method). "JIS" stands for Japanese Industrial Standards. The average fiber diameter of the resin fibers in the fabric component 200 is, for example, 0.4 mm or less and 10 μm or more. Since the gaps between the resin fibers are maintained in the fabric component 200, the average fiber diameter of the resin fibers F ejected from the nozzle of the meltblown device 1 is used as the average fiber diameter of the resin fibers in the fabric component 200. The average fiber diameter of the resin fibers in the fabric component 200 can be 0.4 mm or less and 30 μm or more, or 0.3 mm or less and 10 μm or more. The average fiber diameter of the resin fibers in the fabric component 200 can also be 0.3 mm or less and 30 μm or more.

[0042] like Figure 2 As shown in (a), the fabric member 200 has a shape that bulges outward toward the surface (first surface) 201, for example, along a part of the wearer's body (chest, etc.). In other words, the surface 201 is a bulging surface, while the inner surface (second surface) 202, which is the opposite side of the surface 201, is a concave surface. The thickness of the fabric member 200 varies in the planar direction due to differences in the amount of resin fibers packed. For example, the fabric member 200 includes an upper edge portion 200a, a central portion 200b, and a lower edge portion 200c. The thickness of the central portion 200b is greater than the thickness of the upper edge portion 200a and greater than the thickness of the lower edge portion 200c. The thickness of the upper edge portion 200a is, for example, less than the thickness of the lower edge portion 200c. The thickness of each portion of the fabric member 200 in the planar direction can be appropriately set according to the shape of the part of the wearer's body covered by the member, the required function of the member, and / or the type of fabric, etc.

[0043] Furthermore, the thickness of the fabric component can also be constant in the planar direction. That is, the fabric component can also have a uniform thickness in all parts of the planar direction. In this specification, the "thickness" of the fabric component refers to the thickness of the fabric when it is not worn, and is the thickness when no external force is applied to the fabric component (thickness in its natural state).

[0044] The smoothness of the surface 201 of the fabric component 200 can be higher than the smoothness of the inner surface 202. Smoothness can be determined, for example, by the KES method (measurement performed using a KES-FB4A surface testing machine). The difference in smoothness between the two surfaces can be determined, for example, by their positional relationship with the substrate 50 during manufacturing, as described later. The smoothness of the two surfaces of the fabric component can be appropriately set according to the required function of the component and / or the type of fabric. When the first surface of the fabric component is a convex surface and the second surface is a concave surface, the smoothness of the first surface can be lower than the smoothness of the second surface. If these characteristics are described using a higher-order concept, it can be said that the smoothness of the first surface can be different from the smoothness of the second surface. When the fabric component is a planar component (i.e., a flat component), the smoothness of the first surface can be different from the smoothness of the second surface. In this case, it can also be determined by (e.g.) Figure 1 The smoothness is determined by the surface on the outer side and the surface on the inner side when components (such as the fabric component 300) are assembled on the fabric.

[0045] The smoothness of the first surface of a fabric component can be equal to the smoothness of the second surface.

[0046] like Figure 2 As shown in (b), the fabric component 200 has multiple resin fiber layers that differ in at least one of the following: the type of resin material, the diameter of the resin fiber, and the density of the resin fiber. Figure 2 In the example shown in (b), the fabric component 200 includes, at least in the central portion 200b: a first layer 210 including a surface 201; a third layer 230 including an inner surface 202; and a second layer 220 located between the first layer 210 and the third layer 230. The fabric component 200 has, for example, a three-layer structure. The fabric component 200 has a three-layer structure not only in the central portion 200b, but throughout. In the fabric component 200, for example, the density of the resin fibers in the second layer 220 is lower than either the density of the resin fibers in the first layer 210 or the density of the resin fibers in the third layer 230. That is, the first layer 210 and the third layer 230 are relatively high-density, and the second layer 220 is relatively low-density. The density of the resin fibers in the first layer 210 may be similar to the density of the resin fibers in the third layer 230. The density of the resin fibers in the first layer 210 may also differ from the density of the resin fibers in the third layer 230 (either one may be higher than the other).

[0047] Alternatively, from another perspective, the thickness of the second layer 220 is greater than either the thickness of the first layer 210 or the thickness of the third layer 230. That is, the first layer 210 and the third layer 230 are relatively thin layers, and the second layer 220 is a relatively thick layer. The thickness of the first layer 210 can also be the same as the thickness of the third layer 230. The thickness of the first layer 210 can also be different from the thickness of the third layer 230 (one can be greater than the other). Alternatively, the thickness of the second layer 220 can be greater than only either the thickness of the first layer 210 or the thickness of the third layer 230. In this case, the thickness of the second layer 220 is less than the other of the thicknesses of the first layer 210 and the third layer 230.

[0048] The type of resin material can be changed by altering the type of resin material fed into the meltblown device 1 during the stacking process. The diameter of the resin fibers can be changed by altering the airflow or ejection pressure in the meltblown device 1. The density of the resin fibers can be changed by altering at least one of the following: the airflow in the meltblown device 1, the distance between the nozzle 26 of the meltblown device 1 and the surface 51 of the substrate 50, and the moving speed of the substrate holder 46.

[0049] Furthermore, when the fabric component has multiple resin fiber layers, the number of layers can be two or more. In the case of a two-layer fabric component, the thickness of the second layer can be greater than the thickness of the first layer. That is, the thickness of each layer can be different. In the case of a fabric component with four or more layers, the thickness of any one layer can be greater than the thickness of another layer. That is, the thickness of at least any two layers can be different. Alternatively, all layers can have different thicknesses, or only any two layers can have equal thicknesses. Regarding the density of the resin fibers, the same difference as the thickness can be set for each layer. The density of the resin fibers can also increase as the layer thickness decreases.

[0050] When a garment component has multiple resin fiber layers, the density of the resin fibers in each layer and the thickness of each layer can be appropriately set according to the required function of the component and / or the type of garment. For example, the first layer 210 (the surface layer) and the third layer 230 (the inner layer) of the garment component 200 can be set as relatively high-density and thin layers considering the durability of the garment component 200 (e.g., wash durability). The second layer 220 (the middle layer) of the garment component 200 can be set as a relatively low-density and thick layer considering lightweight and bulkiness. The second layer 220 can also function to impart elasticity to the garment component 200 as a whole.

[0051] Next, the resin fibers for clothing members will be described. The clothing member of the present embodiment is a clothing member including fibers fused to each other, and the fibers include a first resin and a second resin. The first resin is at least one selected from the group consisting of A1 resin: a polyester resin having a melting point of 130°C or higher, A2 resin: a polyolefin resin having a melting point of 130°C or higher, A3 resin: a styrene resin having a melt flow rate of 20 g / 10 minutes or more measured at 230°C under a load of 2.16 kg, and A4 resin: a polyurethane resin. The second resin is at least one selected from the group consisting of B1 resin: a polyester resin having a melting point lower than 130°C, and B2 resin: a polyolefin resin having a melting point of 120°C or lower. As such a clothing member, a melt-blown clothing member obtained by the melt-blown method is preferred. The average diameter of the fibers in the clothing member is not particularly limited and may be 10 μm to 400 μm.

[0052] <First resin> The first resin is a thermoplastic resin, preferably a thermoplastic elastomer. In addition, in this specification, an elastomer means a resin having a glass transition temperature lower than room temperature (25°C) measured by differential scanning calorimetry (DSC), for example. The first resin may be any of the four resins of the above A1 resin to A4 resin. The first resin may be only one resin or two or more resins may be used in combination. The Shore hardness A of the first resin is preferably 50 or more, more preferably 60 to 95, and further preferably 65 to 90. In addition, the Shore hardness A may be the Shore hardness A measured by a hardness tester by the method described in JIS K 6253 or JIS K 7215.

[0053] Relative to 100% by mass of the total amount of the clothing member, the content of the first resin in the clothing member is preferably 60% by mass or more, more preferably 65% by mass or more, and further preferably 70% by mass or more. The upper limit of the content of the first resin in the clothing member is not particularly limited. For example, relative to 100% by mass of the total amount of the clothing member, it may be 95% by mass or 90% by mass.

[0054] <A1 resin> The A1 resin is a polyester resin having a melting point of 130°C or higher. The melting point of the polyester resin can be measured by DSC, for example. The melting point of the polyester resin is preferably 135°C or higher, preferably 140°C or higher, more preferably 145°C or higher, and particularly preferably 150°C or higher. From the viewpoint of processability, the upper limit of the melting point of the polyester resin may be, for example, 200°C or 190°C.

[0055] The polyester resin is not particularly limited, and examples thereof include a polyester resin having a structural unit derived from an aromatic polycarboxylic acid and a structural unit derived from an aliphatic polyol. The aromatic polycarboxylic acid is preferably an aromatic dicarboxylic acid such as terephthalic acid. As the aliphatic polyol, alkylene glycols having 2 to 10 carbon atoms can be mentioned, and ethylene glycol and 1,4-butanediol are preferable.

[0056] The polyester resin may be a block copolymer having a hard segment and a soft segment. The hard segment preferably has, for example, a structural unit derived from an aromatic polycarboxylic acid and a structural unit derived from an aliphatic polyol, and the soft segment preferably has a structural unit derived from an aromatic carboxylic acid and a polyethylene glycol block. As the aliphatic alcohol contained as a structural unit in the hard segment, alkylene glycols having 2 to 10 carbon atoms can be mentioned, and ethylene glycol and 1,4-butanediol are preferable.

[0057] From the viewpoint of lightening the weight of the clothing member, the specific gravity (density) of the polyester resin as the A1 resin is preferably 1.2 or less, and more preferably 1.1 or less. The specific gravity can be measured by, for example, the method of ASTM D792.

[0058] Commercially available products can also be used as the polyester resin of the A1 resin. For example, as the above-mentioned polyester resin having a hard segment and a soft segment, Hytrel (registered trademark) 3001 (manufactured by DU PONT-TORAY CO., LTD.), PELPRENE (registered trademark) P-30B, PELPRENE (registered trademark) P-40B, PELPRENE (registered trademark) P-40H (all manufactured by Toyobo Co., Ltd.) etc. can be mentioned.

[0059] <A2 resin> The A2 resin is a polyolefin resin having a melting point of 130°C or higher. The melting point of the polyolefin resin can be measured by DSC, for example. The melting point of the polyolefin resin is preferably 135°C or higher, preferably 140°C or higher, more preferably 145°C or higher, and particularly preferably 150°C or higher. From the viewpoint of processability, the upper limit of the melting point of the polyolefin resin can be, for example, 200°C or 190°C.

[0060] The olefin units contained in the polyolefin resin are not particularly limited, and are preferably olefins having 2 to 10 carbon atoms such as ethylene and propylene, and more preferably olefins having 2 to 5 carbon atoms. The olefin may be an α-olefin. As the unit contained in the polyolefin resin, propylene (i.e., polypropylene resin) is preferred. In addition, the polypropylene resin may be a homopolymer of propylene or a copolymer containing propylene and other monomer units. The polypropylene resin as a copolymer contains a structural unit derived from propylene as a main component. For example, relative to 100% by mass of the total amount of the polypropylene resin, the content of the structural unit derived from propylene may be 70% by mass or more, 80% by mass or more, or 90% by mass or more. As the copolymer, a copolymer of ethylene and propylene can be cited. The content of the unit derived from ethylene in the copolymer of ethylene and propylene may be 15% by mass or less, or 10% by mass or less.

[0061] The melt flow rate of the polyolefin resin is preferably 5 to 100 g / 10 min, more preferably 10 to 50 g / 10 min, and further preferably 15 to 40 g / 10 min. The melt flow rate may be a value measured at 230 °C using a load of 2.16 kg.

[0062] As the polyolefin resin of the A2 resin, commercially available products can also be used. As such polyolefin resins, for example, TAFMER (registered trademark) PN20300 (manufactured by Mitsui Chemicals, Inc.), WINTEC (registered trademark) WMX03 (manufactured by Japan Polypropylene Co.) etc. can be cited.

[0063] <A3 resin> The A3 resin is a styrenic resin having a melt flow rate of 20 g / 10 min or more measured at 230 °C using a load of 2.16 kg. The melt flow rate is preferably 40 g / 10 min or more, more preferably 70 g / 10 min or more, further preferably 100 g / 10 min or more, still further preferably 150 g / 10 min or more, and particularly preferably 200 g / 10 min or more. In addition, the resin contained in the A3 resin is a resin not contained in the A2 resin.

[0064] The styrenic resin is a polymer containing a structural unit derived from styrene. As the styrenic resin, it may be a homopolymer of styrene or a copolymer of styrene and other monomers. When the styrenic resin is a copolymer, relative to 100% by mass of the total amount of the styrenic resin, the content of the unit derived from styrene is preferably 10 to 40% by mass, more preferably 15 to 30% by mass, and preferably 17 to 25% by mass. As monomers other than styrene contained in the styrenic resin, olefins such as ethylene and butene can be cited.

[0065] As the styrene resin as the A3 resin, commercially available products can also be used. Examples of such styrene resins include Kraton (registered trademark) MD1648 (manufactured by Kraton Corporation).

[0066] <A4 resin> The A4 resin is a polyurethane resin. The melt viscosity of the polyurethane resin at 180 °C is preferably 3000 Pa·s or less, more preferably 2000 Pa·s or less. In addition, the melt viscosity of the polyurethane resin at 170 °C is preferably 4000 Pa·s or less, more preferably 3000 Pa·s or less, and further preferably 2000 Pa·s or less. In addition, the melt viscosity of the polyurethane resin at 160 °C is preferably 3000 Pa·s or less, more preferably 2000 Pa·s or less. In addition, the melt viscosity of the polyurethane resin at 150 °C is preferably 4000 Pa·s or less, more preferably 3000 Pa·s or less. The melt viscosity can be measured, for example, by the temperature-rising method using a Koka-type flowability measuring instrument. As the Koka-type flowability measuring instrument, CFT-500 (manufactured by Shimadzu Corporation) can be used, and as the specific measurement conditions, the load can be set to 196 N, the temperature-rising rate to 2.5 °C / min, and the die to Φ1 mm × L10 mm.

[0067] The polyurethane resin as the A4 resin may also be a block copolymer having a hard segment with a urethane bond and a soft segment. The hard segment preferably has a structural unit derived from a polyisocyanate and a structural unit derived from an aliphatic diol. The polyisocyanate contained as a structural unit in the hard segment may be an aliphatic polyisocyanate or an aromatic polyisocyanate, and is preferably a diisocyanate. The aliphatic diol contained as a structural unit in the hard segment may be an alkylene diol having 2 to 10 carbon atoms (more preferably 2 to 6 carbon atoms). The soft segment preferably has a structural unit derived from a polyisocyanate and a polyester polyol block or a polyether polyol block.

[0068] The Shore hardness A of the polyurethane resin as the A4 resin is preferably 50 or more, more preferably 60 to 95, and further preferably 65 to 90. In addition, the Shore hardness A may be the Shore hardness A measured using a hardness tester by the method described in JIS K 6253 or JIS K 7215.

[0069] As the polyurethane resin as the A4 resin, commercially available products can also be used. For example, as the polyurethane resin having a hard segment and a soft segment containing a polyether polyol block, examples include FORTIMO (registered trademark) XET-T1475 (manufactured by Mitsui Chemicals, Inc.), FORTIMO (registered trademark) XET-T1480 (manufactured by Mitsui Chemicals, Inc.), etc.

[0070] <Second resin> The second resin is a thermoplastic resin, preferably a thermoplastic elastomer. The second resin may be at least one of the above-mentioned B1 resin and B2 resin. The second resin may be only one type of resin, or two or more types may be used in combination.

[0071] Relative to 100% by mass of the total amount of the clothing member, the content of the second resin in the clothing member is preferably 3 to 30% by mass, more preferably 5 to 25% by mass, and still more preferably 7 to 20% by mass.

[0072] <B1 resin> The B1 resin is a polyester resin having a melting point below 130°C. The polyester resin may be a crystalline polyester resin. The lower limit of the melting point of the polyester resin may be room temperature (25°C), for example, it may be 60°C.

[0073] As the polyester resin of the B1 resin, for example, the number-average molecular weight is preferably 8,000 to 50,000, preferably 15,000 to 45,000, and still more preferably 25,000 to 40,000. In addition, the melt viscosity at 200°C is preferably 3,000 to 10,000 dPa·s, more preferably 4,000 to 8,000 dPa·s.

[0074] As the polyester resin of the B1 resin, commercially available products can also be used. As such a polyester resin, for example, Vylon (registered trademark) GM-913 (manufactured by Vylon Co., Ltd.) can be cited.

[0075] <B2 resin> The B2 resin is a polyolefin resin having a melting point below 120°C. The melting point of the polyolefin resin can be measured by DSC, for example. The melting point of the polyolefin resin is preferably 115°C or lower, more preferably 110°C or lower, and still more preferably 105°C or lower. The lower limit of the melting point of the polyolefin resin may be room temperature (25°C), for example, it may be 60°C. [[ID=We]]

[0076] As such a polyolefin resin, a polypropylene resin is preferred. The polypropylene resin may be a homopolymer of propylene or a copolymer containing propylene and other monomer units. The polypropylene resin as a copolymer contains a structural unit derived from propylene as the main component. For example, relative to 100% by mass of the total amount of the polypropylene resin, the content of the structural unit derived from propylene may be 70% or more, may be 80% or more, or may be 90% or more. As the copolymer, a copolymer of ethylene and propylene can be cited. The content of the unit derived from ethylene in the copolymer of ethylene and propylene may be 15% or less, or may be 10% or less. The polypropylene resin preferably has a low stereoregularity. For example, the mmmm fraction is preferably 20 to 70%, preferably 30 to 60%. The mmmm fraction can be measured by nuclear magnetic resonance method (NMR).

[0077] Polyolefin resins preferably have a narrow molecular weight distribution; for example, they also preferably have a polydispersity (weight-average molecular weight / number-average molecular weight) of 1.5 to 2.5.

[0078] Commercially available polyolefin resins can also be used as B2 resins. Examples of such polyolefin resins include: Vistamaxx 8880 (manufactured by Exxon Mobil), Vistamaxx 7050BF (manufactured by Exxon Mobil), L-MODU S400 (manufactured by Idemitsu Kosan Co., Ltd.), and L-MODU S600 (manufactured by Idemitsu Kosan Co., Ltd.).

[0079] The inventors believe the following reasons for improving the shape freedom and bulkiness of clothing components by using both the first and second resins. Firstly, in manufacturing clothing components where fibers are fused together, the molten fibers are brought into contact and fused together. At this time, if the resin has a high melting point, the difference between the melting temperature and the molding temperature when the resin is molded into filaments is small. Therefore, before the molten resin, molded into filaments, comes into contact with each other, the resin temperature easily drops to near its melting point, reducing the adhesion between the fibers. Furthermore, the adhesion to the substrate also decreases when molding the clothing component. Especially for molding substrates with complex structures, fibers with weak adhesion are difficult to fix, making it difficult to control the shape of the clothing component. Since A1 and A2 resins have high melting points, and the crystallinity of such resins is accompanied by increased stereoregularity, they tend to have excellent elasticity and excellent bulkiness in the manufactured clothing components. However, based on the above reasons, it is difficult to manufacture freely shaped clothing components on their own. On the other hand, since B1 and B2 resins have low melting points, they have excellent adhesion, unlike the first resin. Therefore, by using the first and second resins together, due to their excellent adhesion, the shape of the fabric component can be made into the desired shape, and the bulkiness of the fabric component can also be improved.

[0080] There are no particular restrictions on the combination of the first resin and the second resin; any combination may be used, but the following combinations are examples.

[0081] (1) The first resin contains A1 resin and the second resin contains B1 resin.

[0082] (2) The first resin contains A2 resin and the second resin contains B2 resin.

[0083] (3) The first resin contains A3 resin and the second resin contains B1 resin.

[0084] (4) The first resin contains A3 resin and the second resin contains B2 resin.

[0085] In addition, when using multiple first resins, for example, combinations thereof can be listed below.

[0086] (I) A1 resin and A4 resin (II) A2 resin and A3 resin (III) A1 resin and A3 resin In case (I), the content of Al resin is preferably 40 to 80% by mass, more preferably 50 to 70% by mass, relative to 100% by mass of the total amount of the fabric component. Furthermore, in this case, the content of Al resin is preferably 5 to 30% by mass, more preferably 10 to 25% by mass, relative to 100% by mass of the total amount of the fabric component.

[0087] In case (II), the content of A3 resin is preferably 40 to 80% by mass, more preferably 50 to 70% by mass, relative to 100% by mass of the total amount of the fabric component. In addition, in this case, the content of A2 resin is preferably 5 to 30% by mass, more preferably 10 to 25% by mass, relative to 100% by mass of the total amount of the fabric component.

[0088] In case (III), the content of A3 resin is preferably 40 to 80% by mass, more preferably 50 to 70% by mass, relative to 100% by mass of the total amount of the fabric component. In addition, in this case, the content of A1 resin is preferably 5 to 30% by mass, more preferably 10 to 25% by mass, relative to 100% by mass of the total amount of the fabric component.

[0089] <Other Ingredients> The fibers constituting the components of the clothing may also contain components other than the first and second resins. Examples of such components include: colorants, antibacterial agents, thermal insulation materials, conductive materials, antistatic materials, and compatibilizers. Antibacterial agents can be either inorganic or organic. Examples of inorganic antibacterial agents include: Ag-Cu, Ag, and Ag-Zn types, such as Bactekiller BM-102TG (manufactured by Fuji Chemical Industries). Examples of conductive materials include graphite. Examples of antistatic agents include polyoxyethylene sorbitan fatty acid esters, such as RHEODOL TW-L120 (manufactured by Kao Corporation). Examples of compatibilizers include maleic acid-modified polypropylene (e.g., "Polinker PL2400" manufactured by POLYALLOY INC.). The content of the other components is preferably 0.1 to 15% by mass, more preferably 1 to 10% by mass, relative to 100% of the total amount of the clothing components.

[0090] Relative to 100% by mass of the total amount of the fabric component, the combined amount of the first resin and the second resin in the fabric component is preferably 80% by mass or more, more preferably 90% by mass or more, more preferably 95% by mass or more, and more preferably 98% by mass.

[0091] Next, refer to Figure 3 The following describes a fabric component manufacturing system S according to one embodiment. The fabric component manufacturing system S is a system for forming fabric components 200 by melt-blowing using resin materials as raw materials. In the fabric component manufacturing system S, for example, two or more resin materials can be used. The fabric component manufacturing system S includes: a melt-blowing device 1, which uses resin materials as raw materials to generate resin fibers F; and a substrate position control device 40, which holds the substrate 50 in such a way that the fabric component 200 is formed on the substrate 50 with a desired thickness and shape.

[0092] The meltblown apparatus 1 includes: an extrusion section 10 for melting and extruding resin material; an ejection section 20 for ejecting resin material; and an air supply section 30 for supplying high-temperature air to the ejection section 20. Most or all of the extrusion section 10, the ejection section 20, and the air supply section 30 are housed, for example, inside the housing 2.

[0093] The extrusion section 10 includes: a tubular screw section 11 for axially extruding resin material; and a motor 12 for applying a rotational driving force to the screw of the screw section 11. A feed hopper 4 for feeding resin material into the screw section 11 is installed at the upstream end (left side of the figure). The feed hopper 4 protrudes upwards from the housing 2. For example, two different resin materials, namely a first resin material M1 and a second resin material M2, are simultaneously fed from above the feed hopper 4.

[0094] The first resin material M1 and the second resin material M2 can be, for example, granular or powdered. Alternatively, either the first resin material M1 or the second resin material M2 can be granular, and the other can be powdered. Furthermore, two or more types of resins can be simultaneously fed into the feed hopper 4.

[0095] Multiple heaters 14 are provided at multiple locations along the axial direction of the screw section 11. Alternatively, a single large heater 14 extending along the axial direction may also be provided. The heaters 14 heat and melt the resin material within the screw section 11. That is, although the resin materials are different before being fed into the feed hopper 4, they melt and mix together within the screw section 11, becoming homogenized (becoming a mixed resin material). Multiple temperature sensors, such as a first temperature sensor 16, a second temperature sensor 17, a third temperature sensor 18, and a fourth temperature sensor 19, are provided at multiple locations along the axial direction of the screw section 11 to detect the temperature of the molten resin material. An ejector section 20 is connected to the downstream end of the screw section 11.

[0096] The ejection section 20 includes a spinning pump 21, a die 24, and an ejection tube section 22 connecting the spinning pump 21 and the die 24. The spinning pump 21 is, for example, mounted above the axis of the screw section 11, and receives resin material pressed into the screw section 11 and ejects it towards the ejection port side of the die 24 via a die head 23. An ejection port 26 for ejecting resin X is formed at the center of the lower end of the die head 23. This ejection port 26 is an ejection nozzle in the meltblown apparatus 1, having multiple orifices with a specific diameter (aperture). The diameter (aperture) of the ejection port 26 is preferably, for example, 0.1 mm to 0.5 mm, more preferably 0.2 mm to 0.4 mm. As an example, the diameter (aperture) of the ejection port 26 is 0.3 mm. The die head 23 and the ejection port 26 are located at the lower end of the ejection section 20, thus being positioned below and ejecting multiple resin fibers F. An ejection temperature sensor for detecting the temperature of the resin material passing through the ejection nozzle may also be provided. Furthermore, by measuring and adjusting the pressure of the ejection pipe section 22, the ejection pressure of the resin X in the ejection section 20 can be adjusted. The ejection pressure can be adjusted by controlling the rotation speed of the screw section 11 of the meltblown device 1, controlling the spinning pump 21, etc. The ejection amount of resin X can also be adjusted instead of the ejection pressure.

[0097] The air supply section 30 includes an air supply duct 31 for air circulation and a blower 33 installed on the air supply duct 31. Air is drawn in from the upstream end of the air supply duct 31 and compressed by the blower 33. The downstream end of the air supply duct 31, i.e., the connecting part 32, is connected to the mold 24. The high-temperature air supplied by the air supply section 30 flows into the interior of the mold 24, thereby causing the resin fiber F to be continuously ejected from the spray outlet 26. One or more heaters 34 are provided around the air supply duct 31. The heaters 34 heat the air. An air temperature sensor 36 for detecting the air temperature is provided at an appropriate position on the air supply duct 31. In addition, an airflow regulating valve 37 for adjusting the air supply volume (air flow rate) is provided on the spray side of the air supply duct 31. The air volume in the air supply section 30 can be detected by providing an airflow sensor on the air supply duct 31, or the air volume can be calculated based on the rotation speed of the blower 33, for example.

[0098] In the fabric component manufacturing system S and the meltblown device 1, various operating conditions (or operating parameters) including airflow, spray pressure, and nozzle temperature are set in order to achieve the desired fiber diameter in the resin fiber F and the desired adhesion and bulkiness in the fabric component 200. The desired fiber diameter in the resin fiber F is, for example, 10 μm to 0.4 mm.

[0099] The fabric component manufacturing system S includes a control unit and an operation unit (both not shown) for inputting air volume, ejection pressure, the temperature of the resin material in the screw section 11, and / or the temperature of the resin material passing through the ejection nozzle, and adjusting these values ​​(operating conditions or operating parameters) to specific target values. Specific values ​​will be described later. The control unit is a computer equipped with a processor such as a CPU and a storage device including RAM and ROM. The control unit stores a computer program for controlling the operation of the meltblown device 1. The storage device or memory (not shown) may also store programs for various controls of the meltblown device 1. The operation unit may have, for example, a touch panel display. The fabric component manufacturing system S may have a display unit that displays the operating status of the meltblown device 1, such as a liquid crystal display or the aforementioned touch panel display.

[0100] The substrate position control device 40 includes a robotic arm 40A, which is capable of holding the substrate 50 and freely changing the position and orientation of the substrate 50 below the nozzle 26. The substrate position control device 40 includes a base 45 disposed on the system's mounting surface, and the robotic arm 40A is mounted on a support portion 45a of the base 45. The robotic arm 40A has multiple arms. Figure 3 In the example shown, the robotic arm 40A has a first arm 41, a second arm 42, a third arm 43, and a substrate holder 46. The first arm 41 is rotatably mounted relative to the support 45a, the second arm 42 is rotatably mounted relative to the first arm 41, and the third arm 43 is rotatably mounted relative to the second arm 42. Each joint has a first rotation axis L1, a second rotation axis L2, a third rotation axis L3, a fourth rotation axis L4, and a fifth rotation axis L5. The first rotation axis L1 extends, for example, in a vertical direction, and the fifth rotation axis L5 extends along the extending direction of the third arm 43. The second rotation axis L2, the third rotation axis L3, and the fourth rotation axis L4 extend in directions intersecting the extending directions of the first arm 41, the second arm 42, and the third arm 43, and their directions change and they move as the posture of each arm changes. The substrate holder 46 is mounted on the front end of the third arm 43.

[0101] The substrate position control device 40 includes: a drive mechanism for driving the arms 41-43; and a control unit and an operation unit (not shown) for adjusting the position and posture of the substrate holder 46. The control unit is a computer equipped with a processor such as a CPU and a storage device including RAM and ROM. The control unit stores a computer program for controlling the operation of the substrate position control device 40. More specifically, a program for various controls of the meltblown apparatus 1 is stored in a storage device or memory (not shown). The operation unit may include, for example, a touch panel display. The arms 41-43 are linked and operated. The substrate position control device 40 freely adjusts the position and posture of the substrate 50 by driving and controlling the arms 41-43.

[0102] The control unit of the substrate position control device 40 inputs and stores the three-dimensional shape data (3D data) of the fabric component 200 to be manufactured, and controls the position and orientation of the substrate 50 in such a way that the fabric component 200 with a specific thickness and shape is formed on the substrate 50. In this specification, the term "position and orientation of the substrate 50" includes both a stationary state and a moving state of the substrate 50. The term "position and orientation of the substrate 50" also includes the concept of the time during which the substrate 50 maintains its position and orientation when stationary, and also includes the concepts of the moving speed, moving method (linear or curved, planar or three-dimensional, etc.), and the time during which the substrate 50 maintains these characteristics when moving.

[0103] Reference Figure 4 The substrate 50 used in the clothing component manufacturing system S of this embodiment can be described as follows. Figure 4 (a) and Figure 4 As shown in (b), the substrate 50 includes a surface 51 corresponding to the shape of the garment component 200 to be manufactured. The substrate 50 is shape-fixed and can be manufactured, for example, by a three-dimensional lamination apparatus (3D printer). The substrate 50 can be made of resin or metal. The material forming the substrate 50 is determined in a manner that allows the garment component 200 to be well attached to the substrate 50 (i.e., in a manner that prevents the garment component 200 from peeling off from the substrate 50) taking into account the properties of the first resin material M1 and the second resin material M2.

[0104] The substrate 50 includes: a base portion 53 (held portion) for holding the substrate holder 46; an accumulation portion 54 (including a surface 51) for depositing resin fibers; and a connecting portion 55 between them. The base portion 53 has a shape and size that can be embedded or held in the substrate holder 46. The surface 51 of the accumulation portion 54 has a concave portion. Resin fibers F are sprayed onto this concave portion, thereby depositing the resin fibers F.

[0105] like Figure 4As shown in (a), a first-type substrate 50A without pores can be used as the substrate 50. The first-type substrate 50A is not breathable. Such a non-breathable substrate 50A is effective, for example, in the case of manufacturing a garment component where the surface of the component is the substrate side and a smooth surface is required. Furthermore, as... Figure 4 As shown in (b), a second type of substrate 50B containing a plurality of holes 52 can be used as substrate 50. The second type of substrate 50B is breathable. The pore diameter of the holes 52 is preferably 5 mm or less, and smaller is more ideal. In the embodiment, it is set to 0.8 mm. Substrate 50B with such breathability is effective, for example, when manufacturing clothing components with resins with low adhesion.

[0106] Next, the manufacturing method of the fabric component 200 will be described. First, various operating conditions (or operating parameters) including airflow, spray pressure, and nozzle temperature are set in the meltblown device 1. Additionally, the substrate movement path is input into the substrate position control device 40. Furthermore, the meltblown device 1 and the substrate position control device 40 are set under atmospheric pressure, but no pressure difference (suction pressure) is applied to the substrate 50. That is, the manufacturing method of the fabric component 200 in this embodiment involves the lamination or stacking of resin fibers F under normal pressure conditions. In this respect, the manufacturing method of the fabric component 200 in this embodiment differs from conventional meltblown methods known as nonwoven fabric manufacturing methods.

[0107] The term "normal pressure condition" can refer to, for example, atmospheric pressure. It can also refer to pressure conditions slightly different from atmospheric pressure. Normal pressure condition means that no pressure difference (suction pressure) is applied. The substrate 50 is positioned below the nozzle 26 in an open state to the atmosphere.

[0108] Next, the operator of the fabric component manufacturing system S turns on the power to the meltblown device 1 and presses the start button. Each heater is turned on to heat up all parts of the meltblown device 1. After confirming that the temperature has risen sufficiently, the operator feeds the first resin material M1 and the second resin material M2 into the feed hopper 4. The extrusion section 10 melts the first resin material M1 and the second resin material M2 while feeding them out through the screw section 11. Air at a specific temperature is supplied by the air supply section 30.

[0109] The nozzle temperature in the ejection section 20 is preferably about 100°C higher than the melting point of the resin material. The nozzle temperature in the ejection section 20 may vary depending on the type of resin material. The airflow can be appropriately set; a larger airflow is set when it is desired to increase the fiber density (desiring a denser fabric) in the fabric component 200, and a smaller airflow is set when it is desired to decrease the fiber density (desiring a coarser fabric). By setting the airflow, the fiber density or softness of the fabric component 200 can be controlled. Furthermore, the ejection pressure can also be set to a larger or smaller value, similar to the airflow, to control the fiber density or softness of the fabric component 200. While the orifice diameter of the ejection outlet 26 is determined as described above, a larger diameter (coarser) makes it more difficult for the resin fibers F to extend, while a smaller diameter (fineer) reduces productivity. The orifice diameter of the ejection outlet 26 can be determined by considering both ease of extension and high productivity.

[0110] The distance between the nozzle 26 of the die head 23 and the surface 51 of the substrate 50 is set to, for example, a range of 150 to 600 mm. When it is desired to increase the fiber density in the fabric component 200 (to make it denser), the distance is set to be smaller, while when it is desired to decrease the fiber density in the fabric component 200 (to make it coarser), the distance is set to be larger.

[0111] As described above, in the fabric component manufacturing system S, the fiber density or softness in the fabric component 200 is adjusted by adjusting the air volume and the distance between the nozzle 26 and the substrate 50.

[0112] Whether to use type 1 substrate 50A or type 2 substrate 50B for substrate 50 can be appropriately determined according to the fabric component 200. For improving surface smoothness, type 1 substrate 50A is suitable.

[0113] Resin fibers F are sprayed from the meltblown apparatus 1 onto a substrate 50 that is held and adjusted to a specific position and orientation by the substrate holder 46 of the substrate position control device 40. When the substrate 50 is moved, for example, the moving distance is in the range of 150 to 1000 mm, and the moving speed is 0 to 1500 mm / s (0 mm / s means stopping). The angle between the surface 51 of the substrate 50 and the spraying direction of the resin fibers F is adjusted to 30 to 90 degrees. If the substrate 50 is stopped, the fabric component 200 can be hardened, thus making it suitable for use as a structural component.

[0114] In this embodiment, when the fabric component 200 has multiple resin fiber layers, the thickness of the fabric component 200 is changed in the surface direction by altering at least one of the spraying time, airflow, and distance from the nozzle 26 of the resin fiber F to the substrate 50. Furthermore, multiple resin fiber layers are formed by varying at least one of the type of resin material, the diameter of the resin fiber F, and the density of the resin fiber F (see reference). Figure 2 (b)).

[0115] Alternatively, in addition to changing the operating conditions in the planar direction, or instead of changing the operating conditions in the planar direction, at least one of the following can be changed in the vertical direction of the substrate 50: the type of resin material, the resin ejection pressure, the spraying time of the resin fiber F, the air volume, and the distance from the nozzle of the resin fiber F to the substrate 50. This alters the characteristics of the fabric component 200 in the thickness direction. Multiple resin fiber layers can also be formed by changing the operating conditions in the vertical direction of the substrate 50 (see [reference]). Figure 2 (b) The "vertical direction" of the substrate 50 refers to the normal direction of the surface 51 of the substrate 50. The normal direction of the surface 51 of the substrate 50 can be defined regardless of whether it is curved or planar. The normal direction of the surface 51 of the substrate 50 corresponds to the thickness direction of the fabric component 200.

[0116] Additionally, in this specification, "multiple fiber resin layers" refers to layers including: Figure 2 (b) describes a structure with clearly defined boundaries that distinguish each layer, as shown in the diagram, and a (gradual) structure where characteristics change gradually without clearly defined boundaries. In other words, "multiple fiber resin layers" refers to both phased changes and non-phased, continuous changes in the fiber resin layers.

[0117] According to the above description of the clothing component 200 and its manufacturing method (atmospheric pressure meltblowing or non-suction meltblowing) of this embodiment, by appropriately adjusting the density or height of the resin fiber stacking in the thickness direction and / or surface direction of the clothing component 200, the density or thickness and other characteristics of the clothing component can be adjusted. Furthermore, the clothing component 200, constructed from a nonwoven structure, exhibits superior breathability compared to molded bodies made of polyurethane or the like. Compared to clothing components obtained by sewing using nonwoven fabrics, the clothing component constructed from a nonwoven structure eliminates sewing marks (sewing threads, etc.), thus minimizing external impact and resulting in superior appearance, such as smoothness. The manufacturing method of the clothing component 200 employs a meltblowing method and controls the position of the substrate 50 to three-dimensionally deposit resin fibers F on the substrate 50 under atmospheric pressure. The position control of the substrate 50 allows for significant adjustments to the properties of the fabric component 200. Furthermore, since suction or applying pressure differentials is not required, it is easy to manufacture fabric components 200 with complex shapes using substrates 50 of complex shapes.

[0118] In this embodiment, it is particularly possible to adjust the properties of specific locations of the fabric components. In conventional meltblown methods, it is difficult to adjust the properties at specific locations in the thickness or surface direction of the component. That is, it is difficult to locally change the density or thickness of the nonwoven structure in the thickness or surface direction. According to this embodiment, it is possible to adjust the local properties in the thickness and / or surface directions.

[0119] The resin fibers F are piled up while maintaining the gaps between them. By maintaining the gaps between the resin fibers F, the breathability and / or bulkiness of the garment component 200 can be ensured.

[0120] The average fiber diameter of resin fiber F is less than 0.4 mm and more than 10 μm. By reducing the average fiber diameter of resin fiber F (refining), the feel and smoothness can be improved.

[0121] The fabric component 200 has a breathability of less than 0.4 kPa・s / m. If the breathability is improved, it will be even more suitable as a fabric component.

[0122] The fabric component 200 has a shape that bulges out toward the surface 201 in a manner that follows a part of the wearer's body, and the smoothness of the surface 201 is higher than that of the inner surface 202. For example, when the surface 201 is located on the outer side of the fabric, the appearance is improved.

[0123] The thickness of the fabric component 200 varies in the planar direction due to differences in the amount of resin fiber F deposited. Furthermore, in the manufacturing method of the fabric component 200, the thickness of the fabric component 200 in the planar direction is changed by altering at least one of the following: resin spraying pressure, resin fiber F spraying time, airflow, and distance from the resin fiber F nozzle to the substrate. By changing the thickness in the planar direction, the cushioning properties and other characteristics in different parts of the planar direction can be freely adjusted. Additionally, adjustments can be made to minimize the thickness at specific locations in the planar direction.

[0124] Furthermore, in the manufacturing method of the fabric component 200, the characteristics of the fabric component 200 in the thickness direction are changed by altering at least one of the following in the vertical direction of the substrate 50: the type of resin material, the resin ejection pressure, the spraying time of the resin fiber F, the air volume, and the distance from the nozzle of the resin fiber F to the substrate. By changing the characteristics of the fabric component 200 in the thickness direction, it is possible to manufacture, for example, a fabric component having multiple resin fiber layers. Figure 2 (b) the first layer 210, the second layer 220, and the third layer 230, etc. Therefore, the functionality of the garment component 200 can be further improved.

[0125] The fabric component 200 has multiple resin fiber layers that differ in at least one of the following: the type of resin material, the diameter of the resin fiber F, and the density of the resin fiber F. Figure 2 (b) the first layer 210, the second layer 220, and the third layer 230, etc. Furthermore, in the manufacturing method of the clothing component 200, multiple resin fiber layers are formed by varying at least one of the type of resin material, the diameter of the resin fiber F, and the density of the resin fiber F. By having multiple resin fiber layers in the clothing component 200, its functionality as a clothing component can be further improved.

[0126] In the fabric component 200, the thickness of the second layer is greater than the thickness of the first layer. For example, Figure 2 (b) The thickness of the second layer 220 shown is greater than the thickness of the first layer 210. In this case, the second layer 220 can be used to ensure fluffiness.

[0127] In the fabric component 200, the thickness of the second layer is greater than either the thickness of the first layer or the thickness of the third layer. For example, Figure 2(b) The thickness of the second layer 220 shown is greater than the thickness of the first layer 210 and also greater than the thickness of the third layer 230. In this case, the first layer 210 and the third layer 230 have characteristics that take into account the impact on appearance or the impact due to external forces. On the other hand, the second layer 220 can ensure the fluffiness of the fabric component. In particular, in the fabric component 200 used as a bra cup, the upper edge 200a is formed to be thinner, so the upper edge of the cup is soft and has excellent skin-friendliness.

[0128] In the fabric component 200, the density of the resin fibers in the second layer is lower than either the density of the resin fibers in the first layer or the density of the resin fibers in the third layer. For example, Figure 2 (b) The density of resin fibers F in the second layer 220 is lower than that in the first layer 210 and also lower than that in the third layer 230. The second layer 220 ensures the fluffiness of the fabric component 200, and by making the fiber density in the first layer 210 and the third layer 230 higher, the smoothness of the surface 201 is improved, thus enhancing the appearance. Furthermore, it also improves the wash durability of the fabric during washing.

[0129] In the manufacturing method of the fabric component 200, the surface 51 of the substrate 50 has a concave portion, and resin fibers F are sprayed onto the concave portion of the substrate 50 to accumulate the resin fibers F. By spraying resin fibers F onto the concave portion of the substrate 50, the formability can be improved even without applying a pressure difference or removing excess fibers. In addition, a bulging surface 201 is formed corresponding to the concave portion. When the surface 201 of the fabric component 200, such as a bra cup, is located on the outside of the fabric (exposed), the appearance can be improved.

[0130] The manufacturing method for the fabric component includes: a step of preparing a substrate 50 produced by a three-dimensional lamination molding method; a step of holding the substrate 50 in a substrate position control device 40 by a substrate holder 46; and a step of depositing resin fibers F onto the substrate 50 by melt-blowing while moving the substrate holder 46. When the substrate 50 is produced by a three-dimensional lamination molding method, there are fewer restrictions on the shape or structure of the substrate 50, and any three-dimensional shape can be achieved. For example, the base portion 53 held in the substrate holder 46, the depositing portion 54 for depositing the resin fibers F, and the connecting portion 55 between them can be freely manufactured. Therefore, the degree of freedom in the shape of the fabric component 200 is also high. Furthermore, by changing the position and orientation of the substrate holder 46 by the substrate position control device 40, it is also easy to change the type and amount of resin fibers F deposited on each part of the substrate 50.

[0131] Since the fabric component 200 can be formed on the substrate 50 by the movement of the robotic arm 40A, it is easy to link with 3D data. In addition, the fabric component 200 can be easily manufactured based on any 3D data, and it is also easy to make customized products.

[0132] By depositing resin fibers F on the substrate 50, the clothing component 200 has a specific thickness. The clothing component 200 formed on the substrate 50 can be naturally cooled (dissipated heat) or, depending on the situation, actively cooled by blowing air.

[0133] The embodiments of this disclosure have been described above, but this disclosure is not limited to the above embodiments. For example, in the case of manufacturing a planar clothing component, a substrate having a flat surface is used. Furthermore, in the case of manufacturing a clothing component including a tubular portion, such as shorts, resin fibers F are sprayed around a tubular or columnar substrate (having an shape corresponding to a part of the human body). After forming the clothing component, the clothing component is peeled off from the substrate.

[0134] Clothing components can have a single-layer structure. In this case, the single layer can have a variation (distribution) in thickness along the surface direction. The thickness of the single layer can also be uniform.

[0135] Regarding the number of fiber resin layers, any modified form can be constructed according to the manufacturing method disclosed above. That is, the fabric component is not limited to a configuration with a three-layer structure overall. It is also possible for the fabric component to have a three-layer structure in one part of the surface direction and a two-layer structure in another part of the surface direction. It is also possible for the fabric component to have a two-layer structure in one part of the surface direction and a one-layer structure in another part of the surface direction. It is also possible for the fabric component to have a three-layer structure in one part of the surface direction, a two-layer structure in another part of the surface direction, and a one-layer structure in yet another part of the surface direction. These are merely examples, and other combinations regarding the number of layers are also applicable. It is also possible for the number of fiber resin layers to differ between one part and another part of the fabric component in the surface direction. The aforementioned "part in the surface direction" can be the central portion 200b (…). Figure 2 (a) and other parts with a large total thickness (thick part), "another part in the surface direction" can be the part with a smaller total thickness (thin part) other than the central part 200b.

[0136] Furthermore, in the above embodiment, although the first resin and the second resin are separately fed into the feed hopper, the first resin and the second resin may also be in a state of being mixed before being fed into the feed hopper 4 (i.e., a resin blend). The resin blend may also be a powder mixture of powdered first resin and powdered second resin, or it may be a substance that is integrated by pre-melting and mixing the first resin and the second resin and then cooling it. When the first resin and the second resin have been pre-melted and mixed, the resin blend may be a block solid or a substance obtained by pulverizing the solid. The shape of the block solid is not particularly limited and may be any shape such as columnar, spherical, flake, or granular. The other components mentioned above may also be included in the resin blend, or they may be added to the feed hopper 4 separately when the resin blend is introduced into the feed hopper 4.

[0137] When multiple resin fiber layers are formed, other components may be inserted between one resin fiber layer and other resin fiber layers. These other components may not be manufactured using the melt-blowing method. A garment component with a structure for holding other components can be manufactured by placing other sheet-like or plate-like resin components on top of the resin fiber layers midway through the deposition of resin fibers F using the melt-blowing method, and then spraying resin fibers F onto the inserted components.

[0138] <Experimental Example> Tests were conducted to manufacture clothing components using the manufacturing method described above. The conditions for the first test are as follows.

[0139] Manufacturing equipment: MBT-100 manufactured by Shinwa Kogyo Co., Ltd. Resin: Hytrel (registered trademark) 3001 (manufactured by DU PONT-TORAY CO., LTD.) Vylon (registered trademark) GM-913 (manufactured by Vylon Corporation) FORTIMO (registered trademark) XET-T1475 (manufactured by Mitsui Chemicals, Ltd.) Operating conditions: Air volume = 800L / min Ejection pressure (pressure in ejection pipe) = 5 MPa Nozzle-substrate distance = 200mm~400mm The first layer takes 20 seconds to form. The second layer takes 60 seconds to form. The formation time of the third layer = 20 seconds like Figure 5As shown, it was confirmed that in all the resin fiber layers of layer 1 (210), layer 2 (220), and layer 3 (230), the resin fibers F are stacked three-dimensionally in the thickness direction while maintaining the gaps between the fibers. It was confirmed that the fibers are fused together, and although the cross-sectional shape of the fibers changes slightly, the gaps between the fibers are maintained, thereby improving air permeability and bulkiness. Furthermore, it was confirmed that layer 1 (210) and layer 3 (230) are relatively high-density and thin layers, while layer 2 (220) is a relatively low-density and thick layer.

[0140] In addition, the conditions for the second test are as follows.

[0141] Manufacturing equipment: MBT-100 manufactured by Shinwa Kogyo Co., Ltd. Resin: Hytrel (registered trademark) 3001 (manufactured by DU PONT-TORAY CO., LTD.) Vylon (registered trademark) GM-913 (manufactured by Vylon Corporation) FORTIMO (registered trademark) XET-T1475 (manufactured by Mitsui Chemicals, Ltd.) Operating conditions: Air volume = 800L / min Ejection pressure (pressure in ejection pipe) = 5 MPa Nozzle-substrate distance = 200mm~400mm The first layer takes 15 seconds to form. The second layer takes 50 seconds to form. The formation time of the third layer is 15 seconds. like Figure 6 (a) and Figure 7 As shown in (a), the surface 201 formed by the resin fibers F has small and fine irregularities. On the other hand, as... Figure 6 (b) and Figure 7 As shown in (b), the surface formed by the resin fiber F in the inner surface 202 has a large and rough texture. That is, it is confirmed that the smoothness of the surface 201 is higher than that of the inner surface 202.

[0142] Symbol Explanation 1: Meltblowing device; 4: Feed hopper; 26: Spray outlet; 40: Substrate position control device; 46: Substrate holder; 50: Substrate; 100: Bra (clothing material); 200: Clothing component; 201: Surface (first surface); 202: Inner surface (second surface); 210: First layer; 220: Second layer; 230: Third layer; 300: Clothing component; F: Resin fiber; M1: First resin material; M2: Second resin material; S: Clothing component manufacturing system

Claims

1. A method for manufacturing clothing components, wherein the method involves three-dimensionally depositing resin fibers onto a substrate under normal pressure using a melt-blowing method, wherein... By adjusting the distance from the nozzle of the resin fiber to the substrate, at least one of the density of the resin fiber deposited on the substrate and the softness of the fabric component can be controlled.

2. The method for manufacturing a fabric component according to claim 1, wherein, When increasing the density of the resin fibers in the fabric component, the distance is set to be relatively small; The distance is set to be larger when the density of the resin fibers in the fabric component is reduced.

3. The method for manufacturing a fabric component according to claim 1 or 2, wherein, The distance is adjusted to be within the range of 150mm to 600mm.

4. The method for manufacturing a garment component according to any one of claims 1 to 3, wherein, In addition to adjusting the distance, the density or the softness is also controlled by adjusting at least one of the airflow and the resin ejection pressure.

5. A fabric component comprising a nonwoven structure containing resin fibers fused together, wherein, The resin fiber comprises a first resin and a second resin. The first resin is selected from at least one of the following groups: polyester resin having a melting point of 130°C or higher, polyolefin resin having a melting point of 130°C or higher, styrene resin having a melt flow rate of 20 g / 10 min or higher at 230°C, and polyurethane resin. The second resin is selected from at least one of the group consisting of polyester resins having a melting point below 130°C and polyolefin resins having a melting point below 120°C.

6. The fabric component according to claim 5, wherein, The first resin and the second resin are thermoplastic elastomers.

7. The fabric component according to claim 5 or 6, wherein, Relative to 100% by mass of the total amount of the fabric components, the content of the first resin is 60% by mass or more, and the content of the second resin is 3% by mass to 30% by mass.

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