Fiber structure and manufacturing method thereof

Abstract

To provide a fiber structure in which a single yarn of a glass fiber can be applied to a complicated woven fabric such as a Jacquard weaving; and to provide a manufacturing method of the fiber structure.SOLUTION: There is provided a fiber structure formed of a Jacquard weaving and including a plurality of warp yarns and a plurality of weft yarns intersecting with the plurality of warp yarns. The plurality of warp yarns are made of a resin, and the plurality of weft yarns include a single yarn of a glass fiber.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a fiber structure and a method for producing the same. [Background technology]

[0002] For example, Patent Document 1 (JP 2023-63052 A) discloses a composite including a resin molded article containing a thermoplastic resin and a fiber structure that is at least partially in contact with the resin molded article and has a breaking elongation of 50.0% or more, in order to provide a composite that is comfortable to wear on the body and has excellent adhesion between the resin molded article and the fiber structure. Here, the fibers constituting the fiber structure may be glass fibers, and the form of the fiber structure may be a woven fabric.

[0003] Patent Document 1 does not specify in what form the glass fiber is used. However, since a single glass fiber thread is strong but fragile, it is not suitable for manufacturing processes in which stress such as bending and stretching is applied. For example, even if it is put through a loom, it is used for simple fabrics such as plain weave, twill weave, and woven basket weave, but not for complex fabrics such as jacquard weave.

[0004] Furthermore, fabrics using glass fiber include, for example, various nonwoven fabrics and woven fabrics in which both the warp and weft threads are made of glass fiber. However, these are generally used only to the extent of being attached to the backside of an object to be reinforced, and the texture obtained by using the glass fiber has not been actively utilized in the texture or surface appearance of the final product. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2023-63052 A Summary of the Invention [Problem to be solved by the invention]

[0006] Contrary to such common technical knowledge in the prior art, the inventors attempted to supply glass fiber yarn and resin yarn to a jacquard loom to see whether they could weave a fabric, and contrary to their expectations, they were able to produce a woven fabric. Furthermore, when they tried turning some of the resin yarn into heat-shrinkable yarn and heating it, they discovered that, depending on the conditions, it was possible to obtain cloth with a never-before-seen feel and appearance.

[0007] In view of the above, the present invention provides a fiber structure made of a jacquard weave, which allows a single yarn of glass fiber to be used for a complex woven fabric such as a jacquard weave, and a method for producing the same. [Means for solving the problem]

[0008] The present invention, obtained based on the above findings, A fiber structure having a plurality of warp yarns and a plurality of weft yarns intersecting the plurality of warp yarns, the plurality of warp yarns are made of resin; the plurality of weft yarns comprising glass fiber monofilaments; The present invention provides a jacquard woven textile structure characterized by:

[0009] In the fiber structure of the present invention having the above configuration, A part of the plurality of warp yarns is a shrinkable warp yarn, It is preferable that the shrinkable warp yarn has a skip portion at least at one location in the length direction thereof, which skips over a predetermined number of adjacent weft yarns.

[0010] In the fiber structure of the present invention having the above configuration, the fiber structure contains 20 to 120 single glass fiber yarns per 1 cm of width of the fabric. is preferred.

[0011] In the fiber structure of the present invention having the above configuration, the glass fiber single yarn preferably has a denier of 30 to 3000.

[0012] The present invention also provides a method for producing a method for manufacturing a semiconductor device comprising the steps of: A step of weaving a fabric using a plurality of warp threads and a plurality of weft threads intersecting with the plurality of warp threads in a preset pattern; applying a specific treatment to the woven fabric; A method for producing a fiber structure comprising the steps of: the plurality of warp yarns are made of resin; The present invention also provides a method for producing a jacquard woven textile structure, comprising:

[0013] In the method for producing a fiber structure of the present invention having the above configuration, A part of the plurality of warp yarns is a shrinkable warp yarn, The shrinkable warp yarn has a jumping portion at at least one location in the length direction thereof, which jumps over a predetermined number of adjacent weft yarns, Preferably, the plurality of weft yarns comprises a single yarn of glass fiber. Effect of the Invention

[0014] According to the present invention, it is possible to provide a fiber structure made of a jacquard weave, in which a single yarn of glass fiber can be used for a complex woven fabric such as a jacquard weave, and a method for producing the same. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic diagram showing an example of the weave of a fiber structure 1 made of a jacquard weave according to a representative embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, a jacquard woven textile structure and a manufacturing method thereof according to a representative embodiment of the present invention will be described in detail with reference to the drawings. Note that since the drawings are intended to conceptually explain the present invention, the dimensions, ratios, and numbers may be exaggerated or simplified as necessary for ease of understanding, and the present invention is not limited thereto.

[0017] 1. Construction of fiber structure 1 The configuration of a textile structure 1 made of a jacquard weave will be described with reference to Fig. 1. Fig. 1 is a schematic diagram showing an example of the weave of the textile structure 1.

[0018] The fiber structure 1 is a fabric made of a woven material. That is, the fiber structure 1 has a plurality of warp threads 10 and a plurality of weft threads 20 intertwined with the plurality of warp threads 10. The plurality of warp threads 10 is a general term for normal warp threads (other warp threads) 11 and shrinkable warp threads 12, which will be described later, and are made of resin. The plurality of weft threads 20 is a general term for normal weft threads (other weft threads) 21 and glass fiber single threads 22, which will be described later, and the other weft threads 21 are made of resin. The fabric constituting the woven material of the fiber structure 1 may be single-ply or double-ply.

[0019] The plurality of warp threads 10 include normal warp threads 11 and shrinkable warp threads 12 . Here, the normal warp threads 11 may be chemical fibers or resin fibers, and may be made of a resin material such as polyester.

[0020] The shrinkable warp threads 12 shrink in the length direction to a greater extent than the normal warp threads 11 when a specific treatment such as heating is applied, and can also be called heat-shrinkable threads. For example, the shrinkable warp threads 12 are composed of a core and a covering thread wound around the core. The core may be made of a material such as polyurethane that shrinks significantly in the length direction when heated to a certain temperature. The covering threads may be made of the same material as the normal warp threads 11, such as polyester.

[0021] The shrinkable warp yarns 12 in the textile structure 1 have jump parts 12A at least at one location in the longitudinal direction thereof, which jump over a predetermined number of adjacent weft yarns. The jump parts 12A may be exposed on the front side of the textile structure 1 or may be hidden on the back side. The jump parts 12A are arranged according to a preset pattern.

[0022] The weft yarns then include glass fiber (long fiber) monofilaments (yarns) 22. For example, a monofilament of E-glass fiber can be suitably used as the weft yarn, but is not limited thereto. Also, the other weft threads (normal weft threads) 21 can be made of the same material as the normal warp threads 11, for example, polyester.

[0023] In the fiber structure 1, when a specific treatment such as heating is applied, the shrinkable warp yarns 12 shrink in the length direction more than the normal warp yarns 11. At this time, the jump sections 12A shrink more, and the fiber structure 1 as a whole shrinks in the warp direction. As a result, a three-dimensional shape and pattern are formed in the fiber structure 1 according to a preset pattern. Furthermore, sufficient strength can be ensured by the glass fibers contained in the weft yarns 20. Moreover, the hardness of the fiber structure 1 can be adjusted.

[0024] Next, specific examples of materials constituting the fiber structure 1 will be given. As the normal warp threads 11, polyester 50 to 150 (preferably 70 to 80) denier (36 filaments) can be used. Moreover, polyester wound marlon (size processing) can be used as the shrinkable warp thread 12. The shrinkable warp thread 12 can be 50 to 150 denier. The ratio of normal warp threads 11 to shrinkable warp threads 12 can be about 10,000 for the latter 2,000.

[0025] The glass fiber single yarn 22 used as the weft can be 30 to 3000 denier. The glass fiber single yarn 22 can be wound in a wound state. In the case of a single-ply fabric, about 10 to 50 strands can be woven per cm, and in the case of a double-ply fabric, about 30 to 120 strands can be woven per cm. Fabric cannot be made unless the thread count is between 10 and 120 threads per cm. In other words, if the thread count is less than 10 threads per cm, the fabric becomes coarse and loses its regular shape, making it difficult to make fabric, while if the thread count is more than 120 threads per cm, the fabric becomes too dense and hard, losing its flexibility and workability, making it difficult to make fabric that can actually be used. Furthermore, in order to more reliably obtain the effects of the present invention, it is preferable to use glass fiber single threads 22 having a denier of 100 to 300 and to set the number of threads per thread to 20 to 100.

[0026] As a type of glass fiber, E-glass can be preferably used. The composition of E-glass is roughly as follows: SiO252-56(%) Al2O3 12-16(%) CaO, MgO 20~25(%) RO 0~0.8(%) B2O3 5-10(%)

[0027] The glass fiber in this embodiment is a single yarn formed by twisting a strand made of filaments of 4.0 μm to 7.4 μm, and in particular, glass fibers having the following characteristics can be preferably used. [Glass fiber example 1] Filament diameter 5.3μm Number of filaments: 200 Twist count 1.0 / 25mm tex count 11.2g / 1000m Length per mass: 89.2km / kg

[0028] [Glass fiber example 2] Filament diameter 6.4μm Number of filaments: 400 Twist count 1.0 / 25mm tex count 33.7g / 1000m Length per mass: 29.6km / kg

[0029] Furthermore, the glass fiber single yarn 22 may have one turn (Z direction) per 25 mm for a 100 denier equivalent, and one turn (Z direction) per 25 mm for a 300 denier equivalent.

[0030] 2. Method for producing fiber structure 1 Next, a method for producing the fiber structure 1 will be described.

[0031] The method for manufacturing the fiber structure 1 includes a step of weaving a fabric from a plurality of warp threads 10 and a plurality of weft threads 20 intertwined with the plurality of warp threads 10 in a preset pattern (weaving step), and a step of applying a specific treatment to the woven fabric. Here, heating is used as the specific treatment, so the latter step is called the heating step. However, the specific treatment may be any treatment that can shrink the shrinkable warp threads 12, and other treatments such as immersion in a chemical may also be used.

[0032] The warp yarns 10 include normal warp yarns 11 and shrinkable warp yarns 12. The weft yarns 20 include glass fiber single yarns 22 and other weft yarns 21. In the weaving process of this embodiment, for example, wound warp threads 10 and weft threads 20 are used and fed to a jacquard loom to create a jacquard weave. Before the warp threads 10 and weft threads 20 are hung on the loom, the necessary pattern paper is prepared, the threads are dyed, and warping is performed.

[0033] In the heating step, various methods can be used as long as they can heat the woven fabric. For example, ironing, steaming, hot water bathing, etc. can be used. By applying heat in these ways, the shrinkable warp threads 12 are shrunk, and the fabric is made into a three-dimensional structure. The heating conditions can be appropriately adjusted depending on the specifications of the fiber structure 1, but for example, steam at 100°C to 180°C may be applied to the fiber structure 1 for about 1 second to 1 minute, preferably 2 to 3 seconds to 30 seconds.

[0034] The fiber structure 1 thus obtained can reproduce fine and delicate patterns with a high degree of freedom by using jacquard weaving technology. Since patterns can be created by changing the structure of the fabric, not only does the fabric have a three-dimensional appearance and thickness, but the shrinkage of the fabric itself enhances the three-dimensional appearance.

[0035] Furthermore, the glass fiber weft can provide sufficient strength to the fiber structure 1. Moreover, the hardness of the fiber structure 1 can be adjusted by adjusting the composition of the shrinkable warp yarns 12 and the heating conditions.

[0036] Therefore, the fiber structure 1 can be used for various purposes and can be applied to the surface to be decorated. For example, the fiber structure 1 can be used for lighting, interior decoration, furniture, etc. In this regard, in the conventional technology, although a yarn containing glass fiber was woven on a loom, the application was limited to relatively simple fabrics such as plain weave, twill weave, and satin weave. In other words, there was no idea of ​​jacquard weaving using a yarn containing glass fiber. Furthermore, conventionally, fabrics made from yarn containing glass fiber have only been used by attaching them to the back of an object for reinforcement or the like, and this fiber fabric has not been used as a pattern on the front side.

[0037] Although the representative embodiment of the present invention has been described above, the present invention is not limited to only such an embodiment, and various design modifications are possible, and all such design modifications are included in the technical scope of the present invention. For example, metal fibers such as aluminum fibers or carbon fibers may be used in combination with glass fibers. [Explanation of symbols]

[0038] 1. Fiber structure (fabric) 11 Normal warp threads (other warp threads) 12 Shrinkable warp threads 12A Jump Section 21 Normal weft (other weft) 22 Glass fiber single yarn

Claims

1. A fiber structure having a plurality of warp yarns and a plurality of weft yarns intersecting the plurality of warp yarns, the plurality of warp yarns are made of resin; the plurality of weft yarns comprising glass fiber monofilaments; A textile structure made of a jacquard weave characterized by the above.

2. A part of the plurality of warp yarns is a shrinkable warp yarn, The shrinkable warp yarn has a jump portion at least at one location in the length direction thereof, which jumps over a predetermined number of adjacent weft yarns; The fiber structure according to claim 1 ,

3. The fiber structure contains 20 to 120 single glass fiber yarns per 1 cm width of the fabric; The fiber structure according to claim 1 or 2,

4. The glass fiber single yarn has a denier of 30 to 3000; The fiber structure according to claim 1 or 2,

5. A step of weaving a fabric using a plurality of warp threads and a plurality of weft threads intersecting with the plurality of warp threads in a preset pattern; applying a specific treatment to the woven fabric; A method for producing a fiber structure comprising the steps of: the plurality of warp yarns are made of resin; the plurality of weft yarns comprising glass fiber monofilaments; A method for producing a fiber structure comprising a jacquard weave, comprising:

6. A part of the plurality of warp yarns is a shrinkable warp yarn, The shrinkable warp yarn has a jump portion at least at one location in the length direction thereof, which jumps over a predetermined number of adjacent weft yarns; The method for producing a fiber structure according to claim 5,

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