Woven fabric, textile product, and, manufacturing method for woven fabric

Abstract

To provide a textile product capable of temporarily holding formed wrinkle.SOLUTION: A woven fabric in this embodiment has warp yarns, weft yarns, and a fabric body woven with the warp yarns and the weft yarns. At least one of the warp yarns and the weft yarns is a twisted yarn made of a synthetic fiber and heat-sets at a temperature of 100°C or more and 130°C or less. Specifically, at least one of the warp yarns and the weft yarns is the twisted yarn that heat-sets at a second heat-setting temperature of 100°C or higher. Thereby, a formed wrinkle is able to temporarily hold.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a woven fabric, a woven product, and a method for manufacturing a woven fabric.

Background Art

[0002] For example, Patent Document 1 discloses a woven fabric in which polytrimethylene terephthalate fibers are arranged as warp and weft of the fabric, and the ratio (warp CF) / (weft CF) of the warp cover factor (warp CF) to the weft cover factor (weft CF) is 1.2 or more, and the anti-wrinkle rate is 70% or less in the anti-wrinkle rate measurement method defined in JIS L1059-1998 6.2 (Method B, Monsanto method, when dry), and after a sample after the anti-wrinkle rate measurement is loaded with 4.9 N (500 gf) for 5 minutes and suspended, the anti-wrinkle rate measured by JIS L1059-1998 6.1.2 (when dry) is 85% or more, and a woven fabric excellent in shape memory and shape recovery is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a woven product that temporarily holds a shaped wrinkle.

Means for Solving the Problems

[0005] The woven product according to the present invention has a warp, a weft, and a fabric body woven by the warp and the weft, and at least one of the warp and the weft is a twisted yarn formed of a synthetic fiber and heat-set at a temperature of 100°C or higher.

[0006] Preferably, at least one of the warp yarn and the weft yarn is a twisted yarn heat-set at a temperature of 100°C or higher for the second heat setting.

[0007] Preferably, at least one of the warp yarn and the weft yarn is a twisted yarn heat-set at a temperature of 110°C or higher for the second heat setting.

[0008] Preferably, the fabric body is a fabric dyed or imparted with functionality at a temperature lower than the heat setting temperature.

[0009] In addition, the fabric product according to the present invention is a fabric product including a fabric at least in part, the fabric having a warp yarn, a weft yarn, and a fabric body woven by the warp yarn and the weft yarn, wherein at least one of the warp yarn and the weft yarn is a twisted yarn formed of a synthetic fiber and heat-set at a temperature of 100°C or higher.

[0010] In addition, the method for manufacturing a fabric according to the present invention includes a twisting step of heat-setting a yarn formed of a synthetic fiber in a twisted state at a temperature of 100°C or higher to form a twisted yarn, and a step of weaving a fabric body in which at least one of the warp yarn and the weft yarn is the formed twisted yarn.

[0011] Preferably, in the twisting step of forming the twisted yarn, the method includes a first heat setting of heat-setting the yarn in a twisted state, and a second heat setting of heat-setting the yarn in a twisted state again at a temperature higher than the temperature of the first heat setting after the first heat setting.

Advantages of the Invention

[0012] According to the present invention, the formed wrinkles can be temporarily held.

Brief Description of the Drawings

[0013]

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Embodiments for Carrying Out the Invention

[0014] Hereinafter, embodiments according to the present invention will be described with reference to the drawings. However, the scope of the present invention is not limited to the illustrated examples. FIG. 1 is a diagram illustrating the textile product 1 in the present embodiment. FIG. 2 is a diagram illustrating the structure of the textile fabric body 10. For the sake of convenience of explanation, even if there is a space between each thread, in reality, each thread is in close contact with each other. As illustrated in FIGS. 1 and 2, the textile product 1 is, for example, a piece of clothing such as outerwear (e.g., coat, down jacket, etc.), sportswear, or medical clothing (scrub, coat, apron, tunic, etc.). Note that the textile product 1 in this example is outerwear. The textile product 1 has a configuration including at least a part of the textile fabric body 10, and in the textile product 1 of this example, the entire outer fabric is the textile fabric body 10. Note that the present invention is not limited to this, and the textile product 1 may be partially arranged at, for example, joint parts where the frequency of bending and stretching is relatively high in the outer fabric.

[0015] The fabric base body 10 is an example of the fabric in the present invention, and has a weave structure such as plain weave, twill weave, satin weave, double weave, or pebbled weave formed by warp threads 200 and weft threads 202. The warp threads 200 are an example of the warp threads in the present invention, and the weft threads 202 are an example of the weft threads in the present invention. In the fabric base body 10, at least one of the warp threads 200 and the weft threads 202 is a synthetic fiber, and is a yarn (hereinafter referred to as twisted yarn 20: details will be described later) obtained by applying a twist to a raw silk (also called FDY), a false-twisted yarn (hereinafter referred to as a false-twisted yarn), or a non-twisted yarn such as an air-jet yarn (also called a taslan yarn or ATY) and then performing heat processing (heat setting) at a temperature of 100°C or higher. For example, the fabric base body 10 includes a combination of the warp threads 200 which are the twisted yarn 20 and the weft threads 202 which are yarns other than the twisted yarn 20, a combination of the warp threads 200 which are yarns other than the twisted yarn 20 and the weft threads 202 which are the twisted yarn 20, or a combination in which both the warp threads 200 and the weft threads 202 are the twisted yarn 20. Here, the yarn other than the twisted yarn 20 is a yarn that has not been twisted and has not been heat-set at a temperature of 100°C or higher, and is, for example, a yarn having a function such as elasticity, functionality, or adhesiveness (hereinafter referred to as a functional yarn). The elastic yarn is, for example, a polyurethane elastic yarn (so-called spandex) or a heat-sealed polyurethane elastic yarn. The functional yarn is, for example, a yarn mainly composed of functional fibers such as contact heat sensation, contact cold sensation, or antibacterial and deodorizing functions. Acrylic fiber as a heat-sensing functional fiber, rayon or cupra fiber as a cold-sensing functional fiber, or a fiber subjected to antibacterial and deodorizing processing. In addition, if the temperature of the fabric base body 10 is lower than the heat-setting temperature of the twisted yarn 20, it may be arbitrarily dyed by dyeing processing, or may be imparted with performances such as water repellency, water absorption, stain resistance, antibacterial property, or deodorizing property by functionality imparting processing.

[0016] The twisted yarn 20 is formed of a polyester multifilament yarn, for example, raw yarn (FDY), false-twisted yarn, or air-textured yarn which is an untwisted yarn with twist applied thereto, and is a yarn in a state of being heat-treated (heat-set) at a temperature of 100°C or higher, specifically, a yarn heat-set at a temperature of 100°C or higher and 130°C or lower. More specifically, the twisted yarn 20 is a yarn heat-set multiple times with twist applied thereto, and is a yarn heat-set at a temperature of 100°C or higher in the second heat-setting. Note that the twisted yarn 20 in this example is a yarn heat-set twice with twist applied thereto. For example, the first heat-setting temperature is 70°C or higher and 90°C or lower, specifically 75°C or higher and 85°C or lower. Also, the second heat-setting temperature is 100°C or higher and 130°C or lower, specifically 110°C or higher and 125°C or lower. Note that the twisted yarn 20 is not limited to synthetic fibers, and natural fibers are also possible. However, in the case of natural fibers, from the viewpoint that heat-setting at 100°C or higher may cause hardening and a decrease in performance and yarn quality, the twisted yarn 20 is preferably a synthetic fiber.

[0017] Also, the twisted yarn 20 is formed by twisting together, for example, a raw yarn having a thickness of 56 dtex or more and 85 dtex or less and a filament number of 72 to 288. The twisted yarn 20 in this example is formed by twisting together false-twisted yarns having a thickness of 84 dtex and a filament number of 144. Also, the twisted yarn 20 has, for example, a twist number per meter in the range of 300 to 1000 turns, specifically in the range of 400 to 800 turns per meter, and more specifically in the range of 500 to 650 turns per meter. The twisted yarn 20 in this example is twisted with a twist number of 600 turns per meter, that is, medium twist. If the twisted yarn 20 is under a twisting condition where the twist number per meter exceeds 1000 turns, the yarn becomes thin and hard, and it is difficult to maintain a bent state. Therefore, it will return from the bent state to the state before bending, and as a result, it is difficult to impart wrinkles to the fabric. On the other hand, if the twisting condition is such that the twist number per meter is less than 300 turns, the yarn is soft and has a weak stiffness, so it is difficult to maintain a bent state. Therefore, it is difficult to return from the bent state to the state before bending, and as a result, the fabric is soft, an appropriate stiffness is not generated, and a wrinkle shape is not easily formed. Therefore, from the perspective of making the fabric soft and having an appropriate stiffness so that the twisted yarn 20 can temporarily maintain the imparted wrinkled shape and then restore to the state before the wrinkled shape is imparted, it is preferable that the number of twists per meter is in the range of 300 to 1000 turns.

[0018] Next, a method for manufacturing the woven fabric body 10 in the present embodiment will be described. FIG. 3 is a flowchart for explaining the manufacturing method (S10) in the present embodiment. As illustrated in FIG. 3, an operator forms the twisted yarn 20 in the process of step 100, weaves the warp with the twisted yarn 20 formed in the process of step 102, and performs dyeing and functional application processing on the woven warp in the process of step 104, whereby the woven fabric body 10 can be obtained. In step 100 (S100), a person performing the manufacturing work (hereinafter referred to as the operator) forms the twisted yarn 20 using a twisting machine. Specifically, in step 100-2 (S100-2), the operator twists the raw yarn, which is a false-twisted yarn of polyester. For example, the operator twists at a twist number of 600 turns per meter (medium twist).

[0019] In step 100-4 (S100-4), the operator puts the twisted raw yarn into the first heat treatment kettle and performs heat setting (the first heat setting). The operator performs the first heat setting in a vacuum state at a temperature of, for example, 70°C to 90°C for 20 to 40 minutes. Specifically, the operator performs heat setting in a vacuum state at a temperature of 75°C to 85°C for 25 to 35 minutes. In this example, heat setting is performed at a temperature of 80°C for 30 minutes in a vacuum state. After the first heat setting, the operator takes out the raw yarn from the first heat treatment and puts it into the second heat treatment. If S100-4 is not necessary, this step is omitted and the process proceeds to S100-6.

[0020] In step 100-6 (S100-6), the operator puts the yarn after the first heat setting into the second heat treatment kettle, and performs a second heat setting (the second heat setting) on the yarn with twist added at a temperature higher than that of the first heat setting. The operator performs the second heat setting in a vacuum state at a temperature of, for example, 100°C to 130°C for 20 to 40 minutes. Specifically, the operator performs the heat setting in a vacuum state at a temperature of 110°C to 120°C for 25 to 35 minutes. In this example, the heat setting is performed at a temperature of 120°C for 30 minutes in a vacuum state. Then, after the two heat settings are completed, the operator takes out the yarn from the second heat treatment kettle, cools it, and obtains the twisted yarn 20.

[0021] In step 102 (S102), the operator sets the twisted yarn 20 with twist added to the loom through the warping process, and uses the loom to combine the warp 200 and the weft 202, which are the twisted yarn 20, to weave the fabric that becomes the fabric body 10 of the woven fabric. Thereby, the operator obtains the raw fabric formed by the twisted yarn 20.

[0022] In step 104 (S104), the operator dyes the woven raw fabric so as to achieve the desired color matching. The operator immerses the raw fabric in a dye at a temperature lower than the temperature of the heat setting (the first heat setting and the second heat setting) for dyeing. The operator immerses the raw fabric in a dye at a temperature of 130°C or lower, specifically, at a temperature of 100°C or higher and 125°C or lower, more specifically, at a temperature of 110°C or higher and 120°C or lower for dyeing. If the dyeing process is performed at a temperature exceeding 130°C of the heat setting temperature, the twist performance of the twisted yarn 20 will be lost. Therefore, it is preferable to perform the dyeing process at a temperature of 130°C or lower of the heat setting temperature. The dye is, for example, an acid dye, a disperse dye, a reactive dye, or a cationic dye, etc. The operator performs yarn dyeing, plain dyeing (batch type), plain dyeing (continuous type, printing, or product dyeing) with these dyes to dye the raw fabric. Subsequently, the operator performs the functionalization process at a temperature lower than the temperatures of the heat sets (the first heat set and the second heat set). The operator performs the functionalization process on the green fabric at a temperature of 130°C or lower, specifically at a temperature of 100°C or higher and 125°C or lower, more specifically at a temperature of 110°C or higher and 120°C or lower. Similar to the dyeing process, if the functionalization process is performed on the green fabric at a temperature exceeding 130°C of the heat set temperature, the twist performance of the twisted yarn 20 will be lost. Therefore, it is preferable to perform the functionalization process at a temperature of 130°C or lower of the heat set temperature. In addition, if the functionalization process is not necessary, it can be omitted. Also, if S104 is not necessary, this step can be omitted. Thus, according to the manufacturing method of the woven fabric body 10 in this embodiment, by forming a woven fabric with a twisted yarn heat-set at a temperature of 130°C or lower, a woven fabric capable of temporarily preserving the shape of wrinkles can be obtained.

[0023] Next, each example based on the above embodiment will be described with reference to the drawings. <Description of Woven Fabrics in Examples and Comparative Examples> [Example 1] Using a false-twisted yarn made of polyester multifilament yarn with a thickness of 84 dtex and 144 filaments as the raw yarn, the raw yarn is twisted 600 times per meter. The raw yarn in the twisted state is subjected to the first heat set under heat set conditions of 80°C for 30 minutes in a vacuum state, and then the second heat set is performed under heat set conditions of 120°C for 30 minutes in a vacuum state to obtain a twisted yarn. Then, the obtained twisted yarn is used as the warp yarn to weave a twill weave green fabric, which is immersed in a disperse dye for dyeing to obtain the woven fabric of this example. [Example 2] Using a false-twisted yarn made of polyester multifilament yarn with a thickness of 84 dtex and 144 filaments as the raw yarn, the raw yarn is twisted 600 times per meter. The raw yarn in the twisted state is heat set under heat set conditions of 120°C for 30 minutes in a vacuum state to obtain a twisted yarn. Then, the obtained twisted yarn is used as the warp yarn to weave a twill weave green fabric, which is immersed in a disperse dye for dyeing to obtain the woven fabric of this example.

[0024] [Example 3] Using a false-twist yarn made of a polyester multifilament yarn with a thickness of 84 dtex and 144 filaments as the raw yarn, the raw yarn was twisted 600 turns per meter. The raw yarn in the twisted state was subjected to a first heat setting under heat setting conditions of 80 °C for 30 minutes in a vacuum state, and then a second heat setting was performed under heat setting conditions of 110 °C for 30 minutes in a vacuum state to obtain a twisted yarn. Then, the obtained twisted yarn was used as the warp yarn and the plain weave fabric was immersed in a disperse dye for dyeing to obtain the fabric of this example. [Example 4] Using a false-twist yarn made of a polyester multifilament yarn with a thickness of 84 dtex and 144 filaments as the raw yarn, the raw yarn was twisted 600 turns per meter. The raw yarn in the twisted state was subjected to a first heat setting under heat setting conditions of 80 °C for 30 minutes in a vacuum state, and then a second heat setting was performed under heat setting conditions of 100 °C for 30 minutes in a vacuum state to obtain a twisted yarn. Then, the obtained twisted yarn was used as the warp yarn and the plain weave fabric was immersed in a disperse dye for dyeing to obtain the fabric of this example.

[0025] [Comparative Example] Using an untwisted yarn made of a polyester multifilament yarn with a thickness of 84 dtex and 144 filaments as the raw yarn, without performing heat setting on this raw yarn, the plain weave fabric woven with the raw yarn as the warp and weft was immersed in a disperse dye for dyeing to obtain the fabric of this example. That is, the fabric of the comparative example is a fabric without twisted yarn.

[0026] <Test on the method of forming wrinkles>[ The method of forming wrinkles is to hold the sheet surface of the fabric in the spread state with the palm and maintain the held state for 1 to 3 seconds. Then, release the held state. Thereby, wrinkles in a raised state are formed on the fabric. Then, check whether the fabric after wrinkle formation can be stretched by hand to restore to the state before wrinkle formation.

[0027] Figure 4 is a diagram illustrating the states before and after forming wrinkles in Example 1. Figure 5 is a diagram illustrating the states before and after forming wrinkles in Example 2. FIG. 6 is a diagram illustrating the states before and after forming wrinkles in Example 3. FIG. 7 is a diagram illustrating the states before and after forming wrinkles in Example 4. FIG. 8 is a diagram illustrating the states before and after forming wrinkles in the comparative example. <Comparison of the states before and after forming wrinkles in Examples and Comparative Examples> As illustrated in FIGS. 4 to 8, the states before and after forming wrinkles were confirmed in the examples and the comparative example. [Example 1] As illustrated in FIG. 4, in Example 1, when comparing before and after wrinkle formation, it was confirmed that after wrinkle formation, the raised wrinkles were retained. In Example 1, since there was almost no restoration to the state before wrinkle formation during wrinkle formation, it was confirmed that the formed wrinkles were retained almost as they were. Further, in Example 1, when the fabric after wrinkle formation was stretched by hand, it was confirmed that it could be restored to the state before wrinkle formation. [Example 2] As illustrated in FIG. 5, in Example 2, when comparing before and after wrinkle formation, it was confirmed that after wrinkle formation, the raised wrinkles were retained. Since Example 2 was slightly restored to the state before wrinkle formation more than Example 1, it is considered that it was more difficult to retain the wrinkle shape imparted than in Example 1. Further, in Example 2, when the fabric after wrinkle formation was stretched by hand to release the imparted wrinkles, it was confirmed that it could be restored to the state before wrinkle formation.

[0028] [Example 3] As illustrated in FIG. 6, in Example 3, when comparing before and after wrinkle formation, it was confirmed that after wrinkle formation, the raised wrinkles were retained. Since Example 3 was restored to the state before wrinkle formation more than Example 1 and Example 2 during wrinkle formation, it is considered that it was more difficult to retain the wrinkles imparted than in Example 1 and Example 2. Further, in Example 3, when the fabric after wrinkle formation was stretched by hand to release the imparted wrinkles, it was confirmed that it could be restored to the state before wrinkle formation. [Example 4] As illustrated in Fig. 7, in Example 4, when comparing before and after wrinkle formation, it was confirmed that the raised wrinkles were retained after wrinkle formation. Since Example 4 restored to the state before wrinkle formation more than Examples 1 - 3, it is considered that it was more difficult to retain the wrinkles imparted than in Examples 1 - 3. Furthermore, in Example 4, when the fabric after wrinkle formation was stretched by hand to release the imparted wrinkles, it was confirmed that it could be restored to the state before wrinkle formation. [Comparative Example] As illustrated in Fig. 8, in the comparative example, when comparing before and after wrinkle formation, it was confirmed that the raised wrinkles could not be retained after wrinkle formation and it was restored to the state before wrinkle formation. Therefore, it was confirmed that the comparative example could not retain the formed wrinkles more than Examples 1 - 4.

[0029] As described above, according to the fabric of the textile product 1 in the present embodiment, even a fabric made of synthetic fiber yarn such as polyester can temporarily retain arbitrarily formed wrinkles. As a result, it is not necessary to perform shape memory processing on the fabric, and thus an inexpensive shape memory fabric can be manufactured. As described above, the embodiments according to the present invention have been described, but the present invention is not limited thereto, and various changes, additions, etc. are possible without departing from the spirit of the invention.

Explanation of Reference Numerals

[0030] 1... Textile product 10... Fabric body 20... Twisted yarn 200... Warp 202... Weft

Claims

1. A warp, a weft, and a fabric body woven from the warp and the weft are provided, wherein at least one of the warp and the weft is a twisted yarn formed of synthetic fibers and heat-set at a temperature of 100°C or higher Fabric.

2. The fabric according to Claim 1, wherein at least one of the warp and the weft is a twisted yarn heat-set at a temperature of 100°C or higher in a second heat-setting The fabric according to Claim 1.

3. The fabric according to Claim 2, wherein at least one of the warp and the weft is a twisted yarn heat-set at a temperature of 110°C or higher in a second heat-setting The fabric according to Claim 2.

4. The fabric according to Claim 3, wherein the fabric body is a fabric dyed or imparted with functionality at a temperature lower than the heat-setting temperature The fabric according to Claim 3.

5. A textile product including the fabric at least in part, wherein the fabric has a warp, a weft, and a fabric body woven from the warp and the weft and, at least one of the warp and the weft is a twisted yarn formed of synthetic fibers and heat-set at a temperature of 100°C or higher Textile product.

6. A method for manufacturing a fabric, comprising: a twisting step of heat-setting a yarn formed of synthetic fibers in a twisted state at a temperature of 100°C or higher to form a twisted yarn; and a weaving step of weaving a fabric body formed of the twisted yarn formed by at least one of the warp and the weft Method for manufacturing a fabric.

7. In the twisting step of forming the twisted yarn, a first heat-setting of heat-setting the yarn in a twisted state; and after the first heat-setting, a second heat-setting of heat-setting the yarn in a twisted state again at a temperature higher than the temperature of the first heat-setting are included The method for manufacturing a fabric according to Claim 6.

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