Clothing fabric manufacturing method

Abstract

To provide a clothing fabric manufacturing method to repeatedly regenerate a clothing fabric.SOLUTION: A method for manufacturing a clothing fabric F comprises: a removal step S1 to remove a first layer L1 from the used clothing fabric F having a multilayer structure including the first layer L1 and a second layer L2 containing fibers; a fibrillation step 3 to fibrillate the second layer L2 by dry fibrillation and extract the fibers; a mixing step S4 to mix treatment agent with the fibers and generate mixture containing no coloring material; an accumulation step S5 to form a web W to be a new second layer L2 by accumulating the mixture in the air on an air permeable fabric N1 to be a new first layer L1; and a molding step S7 to mold by pressurizing and heating the fabric N1 and the web W.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a fabric for clothing. [Background technology]

[0002] In recent years, various recycling technologies have been investigated to promote the effective use of resources and the reduction of waste. In particular, since it is relatively difficult to recycle colored clothing into clothing fabric, the establishment of recycling technologies is desired. For example, Patent Document 1 discloses a method for producing deinked pulp for reusing printed matter. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-94265 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the technology described in Patent Document 1 had the problem that it was difficult to recycle nonwoven fabric when applied to clothing recycling. Specifically, depending on the type of colorant and the degree of coloring, the deinking performance may not be sufficient for clothing, making it difficult to obtain pulp suitable for clothing fabric. In other words, there was a need for a technology that could repeatedly recycle clothing fabric. [Means for solving the problem]

[0005] The clothing fabric manufacturing method includes the following steps: a removal step of removing a first layer from used clothing fabric having a multilayer structure including a first layer and a second layer containing fibers; a defibration step of dry-defibrating the second layer to extract the fibers; a mixing step of mixing a treatment agent with the fibers to produce a mixture that does not contain a coloring material; a deposition step of depositing the mixture in the air on a breathable fabric that will become the new first layer to form a web that will become the new second layer; and a molding step of pressurizing and heating the fabric and the web to mold them. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a schematic cross-sectional view showing the configuration of a clothing fabric according to an embodiment. [Figure 2] FIG. 10 is a schematic cross-sectional view showing another embodiment of the clothing fabric. [Figure 3] 1 is a flow diagram showing a method for manufacturing fabric for clothing. [Figure 4] 1 is a schematic diagram showing the configuration of a fabric manufacturing device used to manufacture clothing fabric. [Figure 5] 1 is a table showing the manufacturing conditions and evaluation results of clothing fabrics according to the examples. [Figure 6] 1 is a table showing the manufacturing conditions and evaluation results of clothing fabrics according to comparative examples. DETAILED DESCRIPTION OF THE INVENTION

[0007] In the following embodiments, a method for manufacturing reusable clothing fabric will be exemplified and explained with reference to the drawings. In each of the following figures, X, Y, and Z axes are used as mutually orthogonal coordinate axes as necessary, with the direction indicated by each arrow being the + direction and the direction opposite to the + direction being the - direction. The Z axis is a virtual axis along the vertical direction, with the +Z direction being upward and the -Z direction being downward.

[0008] In the fabric manufacturing device 1, which is applied to the clothing fabric manufacturing method of this embodiment and will be described later, the upstream side is the side ahead in the conveying direction of the raw material, fabric, web, clothing fabric, etc. For convenience of illustration, the sizes of the components are different from the actual sizes.

[0009] 1. Fabric for clothing As shown in Figure 1, the clothing fabric F produced by the clothing fabric manufacturing method of this embodiment has a multilayer structure including a first layer L1 and a second layer L2. The first layer L1 includes a base layer L1b and an adhesive layer L1a. The clothing fabric F is formed by laminating, from bottom to top, the base layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, and the second layer L2 in this order. When processing the clothing fabric F into clothing, either the first layer L1 or the second layer L2 may be used on the outer surface of the clothing.

[0010] The thickness of the clothing fabric F is appropriately set depending on the use and shape of the clothing to which it is applied. The thickness of the clothing fabric F is not particularly limited, but is set to, for example, 0.30 mm or more and 1.50 mm or less. This improves the flexibility and strength of the clothing fabric F.

[0011] The first layer L1 is breathable. If the second layer L2 is also breathable, the first layer L1 does not hinder ventilation, imparting breathability to the clothing fabric F. This prevents stuffiness when worn when the clothing fabric F is made into clothing.

[0012] Furthermore, in the production of the clothing fabric F, the breathability of the first layer L1 can be used to promote the formation of fibers, etc., which will become the second layer L2, on the first layer L1. Specifically, the formation of a web containing fibers is promoted by sucking air in which fibers, etc., are dispersed through the first layer L1. The manufacturing method and manufacturing process of the clothing fabric F will be described later in the section on the clothing fabric manufacturing method.

[0013] In this specification, breathability is defined as the amount of air passing through a test piece according to the JIS breathability test (L1096 2010 8.26.1 A method). In this specification, breathability means that the amount of air determined by the above test method is 10 cm 3 / cm 2 - seconds or more.

[0014] The thickness of the first layer L1 is not particularly limited, but is preferably set to, for example, 0.01 mm or more and 0.20 mm or less, which can improve the flexibility and strength of the clothing fabric F.

[0015] The base material layer L1b is breathable and serves as one surface of the clothing fabric F. The second layer L2 serves as the other surface of the clothing fabric F.

[0016] The base material layer L1b is a sheet of polyester-containing woven fabric, knitted fabric, nonwoven fabric, etc. Since polyester has relatively excellent strength, the thinness and strength of the clothing fabric F can be further improved.

[0017] The base layer L1b is not limited to being made of polyester, but may be a sheet containing polyester and other resin, or may be a sheet made of a resin other than polyester.

[0018] The adhesive layer L1a is interposed between the base layer L1b and the second layer L2. The adhesive layer L1a bonds the first layer L1 and the second layer L2 together, ensuring adhesive strength between the first layer L1 and the second layer L2.

[0019] The adhesive layer L1a includes an adhesive. Examples of adhesive materials include known adhesive materials such as polyester resin, acrylic resin, silicone resin, and urethane resin, as well as known adhesives such as epoxy, acrylic, cyanoacrylate, urethane, and vinyl acetate. The adhesive of the adhesive layer L1a may be one that hardens when heated during the molding process of the manufacturing process for the clothing fabric F, which will be described later.

[0020] When the clothing fabric F is reused after use, the first layer L1 and the second layer L2 are peeled off in a removal process described below. The second layer L2 separated from the used clothing fabric F is then reused as the raw material for the second layer L2 of a new clothing fabric F. For this reason, the adhesive strength between the first layer L1 and the second layer L2 is determined with consideration given to the reuse of the second layer L2.

[0021] Specifically, it is preferable that no part of the first layer L1 adheres to the separated second layer L2. Specifically, it is preferable that the adhesive layer L1a and the second layer L2 are peeled at the interface in the removal step. Note that if impurities other than fibers are removed when fibers are extracted from the second layer L2 during production, a small amount of the first layer L1 may adhere to the reused second layer L2.

[0022] The adhesive strength between the first layer L1 and the second layer L2 is adjusted by the material of the adhesive layer L1a and its thickness along the Z axis, etc. Although not particularly limited, for example, by using a polyester resin as the material of the adhesive layer L1a and setting the thickness of the adhesive layer L1a to approximately 80 μm, it becomes possible to cause interfacial peeling at the interface between the adhesive layer L1a and the second layer L2.

[0023] The adhesive layer L1a also has breathability. Specifically, the adhesive layer L1a is formed so as not to impair the breathability of the first layer L1. Examples of the adhesive layer L1a include one in which the above-mentioned pressure-sensitive adhesive or adhesive is applied in a planar mesh pattern, and one having a plurality of holes penetrating in the direction along the Z axis.

[0024] The adhesive layer L1a is not an essential component, and the first layer L1 may be composed of only the base layer L1b. In this case, the first layer L1 and the second layer L2 are bonded together by applying pressure and heat in the molding process during the manufacturing process of the clothing fabric F. Even when the first layer L1 does not have the adhesive layer L1a, the adhesive strength between the first layer L1 and the second layer L2 is such that the second layer L2 can be reused.

[0025] The first layer L1 may be colored. When the base layer L1b and the adhesive layer L1a are made of the above-mentioned materials, they generally have a whitish hue. Therefore, if the second layer L2 is colored, the color difference between the first layer L1 and the second layer L2 will be relatively large. When the clothing fabric F is processed into clothing, the difference in color between the first layer L1 and the second layer L2 is easily noticeable. In contrast, if the first layer L1 is colored in a color similar to that of the second layer L2, the difference in color can be made less noticeable when processed into clothing. Furthermore, when the first layer L1 is used as the surface side of clothing, coloring it in various colors improves the design. Note that coloring here includes not only coloring with a single color, but also forming images such as text, patterns, pictures, and photographs by printing, etc.

[0026] The coloring of the first layer L1 may be performed on one of the surfaces of the clothing fabric F. There are no particular limitations on the method for coloring the first layer L1, and known methods such as digital printing such as an inkjet method or analog printing can be applied. The coloring of the first layer L1 may be performed during the manufacturing stage of the first layer L1, or may be performed during the manufacturing process of the clothing fabric F.

[0027] The second layer L2 is a nonwoven fabric containing a plurality of defibrated fibers and a treatment agent such as a binder. In the following description, the defibrated fibers may be simply referred to as fibers. From the viewpoint of versatility of the recycled and newly manufactured clothing fabric F, it is preferable that the fibers of the second layer L2 be composed of white fibers.

[0028] Here, the second layer L2 may contain fibers that have been dyed in advance with a dye. To facilitate reuse of the second layer L2, the fibers constituting the second layer L2 may be dyed with a dye. On the other hand, it is preferable that the second layer L2 does not contain a coloring material such as a pigment. Incidentally, "not containing a coloring material" means that the second layer L2 does not contain a coloring material that has been intentionally added. The second layer L2 may contain a coloring material such as pigment particles that has been unintentionally mixed in.

[0029] The basis weight of the second layer L2 is 100 g / m 2 More than 180g / m2 It is preferable that the basis weight is equal to or less than 1 / 2. The basis weight is the number of grams per square meter of the surface area along the XY plane of one piece of clothing fabric F. When the basis weight of the second layer L2 is within the above range, it is possible to ensure a balance between thinness and strength in the second layer L2. This makes it possible to further improve the thinness and strength of the clothing fabric F. The basis weight of the second layer L2 also affects the ease of peeling at the interface between the first layer L1 and the second layer L2.

[0030] The basis weight of the second layer L2 is adjusted in the deposition step during the production of the clothing fabric F depending on the deposition amount of the web formed, that is, the thickness of the web.

[0031] The thickness of the second layer L2 is not particularly limited, but is preferably 0.20 mm or more and 0.80 mm or less, for example. This can improve the flexibility and strength of the clothing fabric F. The thickness of the second layer L2 is adjusted by the web thickness described above as well as the web pressure conditions in the molding process during the production of the clothing fabric F.

[0032] If the thickness of the second layer L2 is less than the lower limit of the above range, variations in thickness can easily cause unevenness. Therefore, if the second layer L2 is used on the front side of a garment, the first layer L1 on the back side may be visible through it. Therefore, it is preferable to minimize variations in the thickness of the second layer L2. However, the second layer L2 may have portions with uneven thickness.

[0033] The second layer L2 may be subjected to a pretreatment such as a surface treatment on the first surface SF1 that contacts the first layer L1 or on the second surface SF2 that faces the first surface SF1 on the opposite side. The surface treatment improves various physical properties such as abrasion resistance.

[0034] The surface treatment is not particularly limited, but examples thereof include softening treatment, water repellency treatment, wrinkle prevention treatment, and abrasion resistance treatment. Known fiber treatment agents can be used for these surface treatments. For example, abrasion resistance treatment can suppress pilling on the surface of clothing due to friction, thereby maintaining a good appearance of the clothing.

[0035] The surface treatment may be performed during the manufacturing process of the clothing fabric F, or may be performed after manufacturing the clothing fabric F. In particular, when the surface treatment is performed on the first surface SF1, the second layer L2 and the first layer L1 are produced separately. Then, after the surface treatment is performed on the first surface SF1 of the second layer L2, the first layer L1 and the second layer L2 may be bonded together to manufacture the clothing fabric F.

[0036] The fibers are one of the main components of the second layer L2 and, together with the binder, affect the physical properties of the cushioning material, such as its mechanical strength. The fibers of the second layer L2 are recycled from fibers separated from used clothing fabric F. When initially manufacturing the clothing fabric F, the raw material for the fibers is obtained by defibrating the fabric. From the perspective of resource recycling, it is preferable to use old cloth, such as used clothing, as the fabric. The fibers derived from the second layer L2 may also be mixed with fibers derived from other fabrics.

[0037] Fabrics include knit fabrics, plain weave fabrics, pile fabrics, etc. Fabrics may also include nonwoven fabrics.

[0038] Examples of fibers include naturally-derived fiber materials such as cotton, hemp, wool, silk, and regenerated cellulose, and synthetic fibers such as polypropylene, polyester, and polyurethane.

[0039] The fibers may be one of these materials alone or a combination of two or more. Of the above fiber materials, it is particularly preferable that the fabric contains cotton or wool, from the viewpoints of ease of obtaining secondhand clothing and the physical properties of the fibers.

[0040] The weighted average fiber length of the defibrated fibers is preferably 0.5 mm or more and 2.0 mm or less. This prevents the fibers from becoming excessively short, allowing the fibers to be appropriately entangled with each other and improving the mechanical strength of the second layer L2. The weighted average fiber length is determined by a method in accordance with ISO 16065-2:2007.

[0041] The binder bonds the fibers together in the second layer L2. A thermoplastic or thermosetting resin is used as the binder. Examples of the resin include thermoplastic synthetic resins such as polyester, as well as natural resins such as shellac, rosin, dammar, polylactic acid, plant-derived polybutylene succinate, plant-derived polyethylene, and Kaneka Corporation's PHBH (registered trademark) (Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)). One of these resins may be used alone, or two or more may be used in combination as the binder.

[0042] Examples of the treatment agent other than the binder include various additives, such as flame retardants, antioxidants, ultraviolet absorbers, aggregation inhibitors, antibacterial agents, antifungal agents, waxes, and mold release agents.

[0043] As shown in Figure 2, the clothing fabric F may have a multi-layer structure including a first layer L1, a second layer L2, and a third layer L3, as an alternative to the two-layer structure described above. The three-layer structure of this clothing fabric F is formed by sandwiching the second layer L2 between the lower first layer L1 and the upper third layer L3. The first layer L1 and the second layer L2 have the same structure as described above. When processing the clothing fabric F of this form into clothing, either the first layer L1 or the third layer L3 may be used on the outer surface of the clothing.

[0044] The thickness of the clothing fabric F of this embodiment is set appropriately depending on the use and form of the clothing to which it is applied. The thickness of the clothing fabric F of this embodiment is not particularly limited, but is, for example, 0.30 mm or more and 1.50 mm or less. This allows the clothing fabric F to have improved flexibility and strength.

[0045] The third layer L3 has an adhesive layer L3a and a base layer L3b. The third layer L3 is not particularly limited, and the first layer L1 may be used. That is, in the third layer L3, the adhesive layer L1a of the first layer L1 corresponds to the adhesive layer L3a, and the base layer L1b of the first layer L1 corresponds to the base layer L3b. The first layer L1 is turned over in the direction along the Z axis and attached to the second layer L2 as the third layer L3. In this case, too, the adhesion between the adhesive layer L3a and the second layer L2 should have the same properties as the adhesion between the adhesive layer L1a and the second layer L2, taking into consideration separation of the second layer L2.

[0046] The third layer L3 may be colored. For example, if the color tone of the first layer L1 and the color tone of the third layer L3 are different, the color tone will change between the front and back of the garment, improving the design.

[0047] 2. Manufacturing method of clothing fabric The manufacturing method of the clothing fabric F according to this embodiment is an example of the manufacturing method of the clothing fabric of the present invention. The manufacturing method of the clothing fabric F includes a step of separating the second layer L2 from the used clothing fabric F, extracting fibers from the second layer L2, and reusing the fibers in the second layer L2 of a new clothing fabric F.

[0048] As shown in FIG. 3, the manufacturing method of clothing fabric F according to this embodiment includes a removing step S1, a raw material supplying step S2, a defibrating step S3, a mixing step S4, a coloring step S11, a stacking step S5, an attaching step S6, a shaping step S7, and a cutting step S8.

[0049] In the manufacturing method of the clothing fabric F, the clothing fabric F is manufactured through the steps from the upstream removing step S1 to the downstream cutting step S8 in the above order.

[0050] A specific example of a method for manufacturing clothing fabric F will be described together with a fabric manufacturing device 1 that manufactures clothing fabric F. The fabric manufacturing device 1 of this embodiment is an example and is not limited to the following configuration.

[0051] As shown in Figure 4, the fabric manufacturing apparatus 1 is equipped with, from upstream to downstream, a supply section 5, a crushing section 10, a defibrating section 30, a mixing section 60, a depositing section 100, a web conveying section 70, a shaping section 150, and a cutting section 160. The fabric manufacturing apparatus 1 also includes a control section 28 that performs integrated control of the operation of each of the above components. The fabric manufacturing apparatus 1 manufactures clothing fabric F from raw material C.

[0052] The removing step S1 is performed manually or by a device (not shown) separate from the fabric manufacturing device 1. In the removing step S1, a first layer L1 is removed from the clothing fabric F of used clothing to obtain a second layer L2. In the removing step S1, used clothing fabric F that has been tailored into clothing or the like is handled. Since the collected used clothing is expected to vary in shape, size, etc., the removing step S1 may also be performed manually.

[0053] Specifically, after removing sewing threads and the like, the first layer L1 and the second layer L2 are separated from the edge of the clothing fabric F. If the clothing fabric F has a third layer L3, the second layer L2 and the third layer L3 are also separated.

[0054] In the removing step S1, as described above, it is preferable that the first layer L1 and the third layer L3 are not attached to the separated second layer L2. A device having the same function as the above manual operation may be attached to the dough manufacturing apparatus 1.

[0055] The separated second layer L2 becomes the raw material C for a new second layer L2. Fibers extracted from the raw material C are reused for the second layer L2 of a new clothing fabric F. Then, the process proceeds to the raw material supply step S2.

[0056] The raw material supply step S2 is performed in the supply unit 5. The supply unit 5 supplies the raw material C to the crushing unit 10. The supply unit 5 is equipped with, for example, an automatic feed mechanism (not shown), and continuously and automatically feeds the raw material C into the crushing unit 10.

[0057] The crushing unit 10 shreds the raw material C supplied from the supply unit 5 into small pieces in an atmosphere such as the air. The crushing unit 10 is a shredder or cutter mill having crushing blades 11. The raw material C is shredded by the crushing blades 11 into small pieces of raw material C. The planar shape of the small pieces is, for example, several mm square or irregular. The small pieces are collected in the quantitative supply unit 50.

[0058] The constant quantity supply unit 50 weighs the small pieces and supplies a constant amount to the hopper 12. The constant quantity supply unit 50 is, for example, a vibrating feeder. The small pieces supplied to the hopper 12 are transported through the pipe 20 and reach the inlet 31 of the defibrating unit 30. They then proceed to the defibrating step S3.

[0059] The defibrating step S3 is carried out in the defibrating unit 30. In the defibrating step S3, the small pieces derived from the second layer L2 are defibrated in a dry manner to extract the fibers contained in the small pieces of raw material C. The defibrating unit 30 includes an inlet 31, an outlet 32, a stator 33, a rotor 34, and an airflow generating mechanism (not shown). The small pieces of raw material C are introduced into the defibrating unit 30 through the inlet 31 by the airflow from the airflow generating mechanism. In this specification, "dry" refers to a process carried out in air such as the atmosphere, rather than in a liquid such as water.

[0060] The stator 33 and the rotor 34 are disposed inside the defibrating unit 30. The stator 33 has a substantially cylindrical inner surface. The rotor 34 rotates along the inner surface of the stator 33. The small pieces of raw material C are sandwiched between the stator 33 and the rotor 34 and defibrated by the shear force generated between them.

[0061] The fibers produced in the defibrating unit 30 are discharged into the pipe 40 from the discharge port 32. The pipe 40 communicates with the inside of the defibrating unit 30 and the inside of the deposition unit 100. The fibers are transported from the defibrating unit 30 to the deposition unit 100 by the airflow generated by the airflow generating mechanism. A mixing unit 60 is provided in the pipe 40 between the defibrating unit 30 and the deposition unit 100.

[0062] Although not shown in the figures, the fabric manufacturing apparatus 1 may be provided with a separation mechanism between the defibrating unit 30 and the mixing unit 60 that removes impurities contained in the defibrated fibers. Examples of the separation mechanism include well-known devices such as sieves. The separation mechanism reduces the impurity content, making it possible to supply high-purity fibers to a new second layer L2. The process then proceeds to the mixing step S4.

[0063] The mixing step S4 is performed in the mixing section 60. In the mixing step S4, a treatment agent serving as a binder is mixed with the fibers to produce a mixture that does not contain coloring materials. The mixing section 60 includes hoppers 13 and 14, supply pipes 61 and 62, and valves 65 and 66. The mixing section 60 produces a mixture by mixing the treatment agent serving as a binder with the fibers in the air. Note that "not containing coloring materials" as used here means that no coloring materials are intentionally added to the mixture. Therefore, the coloring materials do not include coloring materials such as dyes that have permeated the fibers or coloring materials that have been unintentionally mixed in.

[0064] The hopper 13 communicates with the inside of the pipe 40 via a supply pipe 61. A valve 65 is provided in the supply pipe 61 between the hopper 13 and the pipe 40. The hopper 13 supplies the binder into the pipe 40. The valve 65 adjusts the mass of the binder supplied from the hopper 13 to the pipe 40. This adjusts the mixing ratio of the fibers and the binder. The binder may be supplied in the form of powder or particles, or may be supplied in a molten state.

[0065] The hopper 14 communicates with the inside of the pipe 40 via a supply pipe 62. A valve 66 is provided in the supply pipe 62 between the hopper 14 and the pipe 40. The hopper 14 supplies the additive into the pipe 40. The valve 66 adjusts the mass of the additive supplied from the hopper 14 to the pipe 40. This adjusts the mixing ratio of the additive to the fibers and the binder. The additive may be mixed with the binder in advance and then supplied from the hopper 13.

[0066] The fibers, binder, etc. are mixed to form a mixture while being transported through the pipe 40 to the deposition unit 100. To promote the generation of the mixture in the pipe 40 and to improve the transportability of the mixture, a blower or the like that generates an air current may be provided in the pipe 40. The mixture is introduced from the pipe 40 into the deposition unit 100 via the connection unit 42. Then, the process proceeds to the deposition step S5.

[0067] In addition, when the first layer L1 of the clothing fabric F to be manufactured is to be colored, a coloring step S11 is carried out prior to the depositing step S5. The coloring step S11 will be described later.

[0068] The deposition step S5 is carried out in the deposition unit 100. In the deposition step S5, the mixture is deposited in the air on the breathable fabric N1 to form a web W that will become the new second layer L2. The fabric N1 will become the new first layer L1 of the garment fabric F to be manufactured. In the following description, the new first layer L1 and new second layer L2 of the garment fabric F to be manufactured will also be simply referred to as the first layer L1 and the second layer L2, respectively.

[0069] The deposition unit 100 deposits the mixture in the air on the breathable fabric N1 that will become the first layer L1, to produce the web W that will become the second layer L2. In other words, the second layer L2 is formed by depositing a mixture containing defibrated fibers and a treatment agent in the air on the fabric N1 that will become the first layer L1. This makes it possible to easily form the web W of the second layer L2. Furthermore, the basis weight can be easily changed.

[0070] The deposition unit 100 has a drum unit 101, a housing unit 102 that houses the drum unit 101, and a dough supply unit 71 that supplies dough N1. The deposition unit 100 takes the mixture into the drum unit 101 from the pipe 40. Then, the mixture is deposited on the dough N1 supplied from the dough supply unit 71 in a dry manner.

[0071] Below the accumulation unit 100, a web transport unit 70 including a mesh belt 122 and a suction mechanism 110 is disposed. The suction mechanism 110 is disposed opposite the drum unit 101 in the direction along the Z axis, with the mesh belt 122 sandwiched therebetween.

[0072] The drum unit 101 includes a blade member 101a that is driven to rotate by a motor (not shown), and a substantially cylindrical sieve unit 101b that is disposed to cover mainly the lower part of the blade member 101a. The blade member 101a loosens tangled fibers as it rotates. The sieve unit 101b allows particles such as fibers and mixtures that are smaller than the mesh size of the sieve to pass from the inside to the outside. As a result, the tangled fibers of the mixture in the drum unit 101 are loosened and dispersed into the air within the housing unit 102.

[0073] The fabric supply unit 71 continuously feeds the roll-shaped fabric N1 onto the mesh belt 122. At this time, the adhesive layer L1a of the fabric N1 faces upward. This brings the adhesive layer L1a into contact with the web W. If a release paper is attached to the adhesive layer L1a of the fabric N1, the fabric supply unit 71 may be equipped with a separation mechanism that separates the release paper from the fabric N1.

[0074] Here, the coloring step S11 is performed before the stacking step S5. In the coloring step S11, the fabric N1 that will become the new first layer L1 is colored with pigment ink. This makes it easier to handle small-lot production of a wide variety of items, as the first layer L1 is colored during the manufacturing process of the clothing fabric F. Note that the coloring step S11 is not limited to coloring the entire surface of the fabric N1 with a single color. In the coloring step S11, images such as text, patterns, pictures, and photographs may also be printed.

[0075] Although not shown in the figure, a coloring device that performs the coloring step S11 is disposed between the fabric supply unit 71 and the stacking unit 100. The fabric N1 is colored from the downward-facing side by the coloring device while being sent out from the fabric supply unit 71 and before reaching the stacking unit 100.

[0076] The coloring device is not particularly limited, and examples thereof include known devices such as an ink ejection device and an ink application device. The fabric manufacturing device 1 uses an ink ejection device including an inkjet head. This makes it possible to easily print images such as color patterns, text, pictures, and photographs on the fabric N1 with high resolution.

[0077] Here, a pre-colored material may be used as the fabric N1. In this case, the coloring step S11 is omitted. Note that the coloring step S11 is not an essential step in the manufacturing method of the clothing fabric F, and the coloring device may be omitted.

[0078] A pretreatment step may be carried out before the coloring step S11. In the pretreatment step, the surface of the fabric N1 that will become the new first layer L1 is pretreated. Specifically, as the pretreatment, a surface treatment such as a fixing treatment is performed on the fabric N1. The pretreatment improves the fixability of the pigment ink, and can improve the abrasion resistance and washing fastness of the clothing fabric F to be manufactured.

[0079] The pretreatment process may be performed on the fabric N1 before the raw roll of fabric N1 is loaded into the fabric supply section 71, or may be performed upstream of the coloring device after it has been sent out from the fabric supply section 71. When the pretreatment process is performed in the fabric manufacturing apparatus 1, the pretreatment device is disposed between the fabric supply section 71 and the coloring device.

[0080] The pretreatment device is not particularly limited, and examples thereof include known devices such as a device for ejecting a pretreatment liquid and a device for applying a pretreatment liquid.

[0081] Returning to the deposition step S5, the mixture containing fibers is dispersed from inside the sieve unit 101b into the air inside the housing unit 102. Then, the mixture containing fibers is randomly deposited above the fabric N1 being transported on the mesh belt 122. Therefore, it becomes difficult for the fibers in the web W to be oriented in a specific direction.

[0082] The sieve unit 101b does not need to have the function of separating large fibers and the like from the mixture. That is, the drum unit 101 may loosen the fibers of the mixture and release all of the mixture into the housing unit 102. The mixture dispersed in the air inside the housing unit 102 is deposited on the surface above the fabric N1 by gravity and the suction force of the suction mechanism 110.

[0083] The basis weight of the clothing fabric F is adjusted by the basis weight of the fabric N1 and the web W. The basis weight of the web W is adjusted by the rotation speed of the blade members 101a, the amount of mixture supplied per hour to the deposition section 100, the conveying speed of the fabric N1 by the mesh belt 122, etc.

[0084] The mixing ratio of the fibers to the treatment agent is not particularly limited and is adjusted appropriately depending on the type of treatment agent. For example, when a binder is used as the treatment agent, the mass ratio of the fibers to the binder in the web W is preferably in the range of 9:1 to 5:5 (fiber to binder). This ensures a balance of the physical properties of the clothing fabric F.

[0085] The web transport unit 70 includes a mesh belt 122 and a suction mechanism 110. The web transport unit 70 promotes deposition of the mixture on the fabric N1 by the suction mechanism 110. The web transport unit 70 also transports the web W formed from the mixture downstream by the rotation of the mesh belt 122.

[0086] The suction mechanism 110 is disposed below the drum unit 101. The suction mechanism 110 sucks air from inside the housing unit 102 through a plurality of holes in the mesh belt 122 and the breathable fabric N1. As a result, the mixture discharged to the outside of the drum unit 101 is sucked downward together with the air and piled up on the upper surface of the fabric N1. A known suction device such as a blower is used for the suction mechanism 110.

[0087] The mesh belt 122 has a plurality of holes that allow air to pass through but prevent fibers and binders contained in the mixture from passing through. The mesh belt 122 is an endless belt that is stretched by four tension rollers 121.

[0088] The mesh belt 122 has its upper surface moving downstream due to the rotation of the tension roller 121. In other words, the mesh belt 122 rotates clockwise in FIG. 4. As the mesh belt 122 is rotated by the tension roller 121, the mixture is continuously deposited to form the web W. The web W contains a relatively large amount of air and is soft and inflated. The web W, together with the fabric N1, is transported downstream as the mesh belt 122 moves.

[0089] A humidifier 130 may be disposed downstream of the deposition unit 100 to spray water onto the web W to humidify it. This prevents fibers, binders, and the like contained in the web W from scattering. Alternatively, a water-soluble treatment agent may be added to the water used for humidification, and the web W to become the second layer L2 may be subjected to a surface treatment in parallel with the humidification.

[0090] The web W and fabric N1 are transported downstream by the mesh belt 122, peeled off from the mesh belt 122, and drawn into the dancer roller 141. The dancer roller 141 is provided to ensure the processing time for the downstream forming step S7. More specifically, since the forming step S7 is a batch process, the dancer roller 141 moves up and down relative to the web W and fabric N1 continuously supplied from the accumulation section 100 to ensure the processing time for the forming step S7. The web W and fabric N1 proceed downstream via the dancer roller 141.

[0091] Here, when manufacturing the clothing fabric F having the above-mentioned third layer L3, the attaching step S6 is carried out after the stacking step S5 and before the shaping step S7. In the attaching step S6, fabric N2 that will become the new third layer L3 is attached to the upper surface of the web W. This makes it possible to manufacture the above-mentioned different type of clothing fabric F.

[0092] The attaching step S6 is performed by the fabric supply unit 72 and an attaching device (not shown). The fabric supply unit 72 continuously sends out the roll-shaped fabric N2 above the web W. At this time, if the fabric N2 has an adhesive layer L3a, the adhesive layer L3a of the fabric N2 faces downward. This brings the adhesive layer L3a into contact with the web W. If a release paper is attached to the adhesive layer L3a of the fabric N2, the fabric supply unit 72 may be equipped with a separation mechanism that separates the release paper from the fabric N2.

[0093] The bonding device bonds the upper surface of the web W to the lower surface of the material N2. The bonding device is, for example, a pressure roller, and bonds the web W and the material N2 together while suppressing wrinkles and the inclusion of large air bubbles.

[0094] The fabric N2 may be colored by the fabric manufacturing apparatus 1 in the same manner as the fabric N1, or a pre-colored fabric N2 may be used. When coloring the fabric N2 by the fabric manufacturing apparatus 1, a coloring device similar to that for the fabric N1 is disposed between the fabric supply unit 72 and the attachment device.

[0095] When manufacturing a clothing fabric F that does not have the third layer L3, the attaching step S6 is omitted. In this case, the fabric supply unit 72 and the attaching device may be omitted from the fabric manufacturing apparatus 1. The attaching step S6 may be performed upstream of the dancer roller 141. Then, the fabric N1, the web W, and the fabric N2 proceed together to the forming step S7.

[0096] The forming step S7 is carried out in the forming unit 150. In the forming step S7, the fabrics N1, N2 and the web W are pressurized and heated to form a strip-shaped clothing fabric F. The forming unit 150 is a heat press device and includes an upper substrate 152 and a lower substrate 151. The upper substrate 152 and the lower substrate 151 sandwich and pressurize the web W and fabrics N1, N2, and also heat the web W and fabrics N1, N2 using built-in heaters. In the forming step S7, the forming step S7 may be carried out continuously using a pair of heating rollers or the like.

[0097] Web W is compressed vertically by pressure, increasing its density, and heated, the binder melts and spreads between the fibers. When heating is stopped and the binder solidifies, the fibers are bonded together by the binder. Furthermore, fabrics N1 and N2 adhere to web W, with fabric N1 becoming the first layer L1, web W becoming the second layer L2, and fabric N2 becoming the third layer L3.

[0098] The pressure and heat conditions in the forming unit 150 are adjusted as appropriate depending on the desired density of the clothing fabric F and the melting point or hardening temperature of the binder. Although not particularly limited, the pressure conditions are, for example, 0.01 MPa or higher, and the heat conditions are, for example, 90°C or higher. The forming unit 150 combines the fabrics N1, N2 and the web W into a belt-shaped clothing fabric F. The process then proceeds to cutting step S8.

[0099] The cutting step S8 is carried out in the cutting section 160. The cutting section 160 adjusts the shape of both ends of the belt-shaped clothing fabric F. The cutting section 160 is equipped with a vertical blade (not shown).

[0100] The vertical blade cuts the belt-shaped clothing fabric F in the direction along the direction of travel. This causes both ends of the clothing fabric F to be cut evenly. The belt-shaped clothing fabric F is then wound into a roll to become a bolt of fabric. The cutting unit 160 may also be equipped with a horizontal blade that cuts in a direction intersecting the direction of travel of the clothing fabric F. In this case, the clothing fabric F is cut into single sheets of approximately rectangular or other shapes. In this way, the clothing fabric F is manufactured.

[0101] According to this embodiment, the following effects can be obtained.

[0102] It is possible to manufacture a clothing fabric F that can be easily reused repeatedly. Specifically, the manufactured clothing fabric F includes a first layer L1 that can be colored to ensure design, and an uncolored second layer L2. Therefore, by separating the first layer L1 from the second layer L2, fibers that do not require deinking treatment are obtained from the second layer L2. The obtained fibers can be easily reused as a new second layer L2. Therefore, it is possible to provide a manufacturing method for a clothing fabric F that can be easily reused repeatedly.

[0103] For example, it will be easier to recycle clothing that holds personal sentimental value into new clothing fabric, making it easier to recycle old clothing and remake it into new clothing, continuing to reuse it for generations.

[0104] 3. Examples and Comparative Examples The effects of the present invention will be explained in more detail below with reference to examples and comparative examples. The layer structures, manufacturing conditions, and evaluation results of Examples 1 to 6 and Comparative Examples 1 to 5 are shown in FIGS. 5 and 6. In the following description, Examples 1 to 6 may be collectively referred to simply as Examples, and Comparative Examples 1 to 5 may be collectively referred to simply as Comparative Examples. The present invention is not limited in any way by the following examples.

[0105] 3.1. Preparation of recycled clothing fabric As shown in Figures 5 and 6, in the examples and comparative examples, first, a recycled clothing fabric F0 was prepared. Specifically, in examples 1 to 5 and comparative examples 1 and 2, the two-layer structure shown in Figure 1 was applied as the recycled clothing fabric F0. In example 6 and comparative examples 3 to 5, the three-layer structure shown in Figure 2 was applied as the recycled clothing fabric F0. In the following description, the recycled clothing fabric F0 will also be simply referred to as fabric F0.

[0106] In Example 1, white cotton cloth was used as fabric C, the raw material for the second layer L2. Specifically, in the raw material supply step S2, fabric C was roughly crushed into approximately rectangular pieces with long sides of 1 mm to 30 mm using a cutter mill manufactured by Makino Sangyo Co., Ltd. In the production of the clothing fabric F0, the removing step S1 of the above embodiment was omitted, and fabric C that had not undergone the removing step S1 was used. Next, in the defibrating step S3, the small pieces were defibrated into fibers in the same manner as in the defibrating step S3 of the above embodiment.

[0107] Next, in the mixing step S4, the fibers and the binder were mixed by air stirring in a mass ratio of 10 to 3. A thermoplastic resin was used as the binder.

[0108] Next, prior to the deposition step S5, a coloring step S11 was performed on the white fabric N1. A 0.1 mm thick polyester nonwoven fabric was used as the fabric N1. The fabric N1 had a base layer L1b made of polyester fiber and an adhesive layer L1a containing thermoplastic polyester. In the coloring step S11, an image was printed on the entire surface of the fabric N1, rather than coloring it entirely.

[0109] First, the surface of the substrate N1 opposite the adhesive layer L1a, i.e., the surface of the base layer L1b, was pretreated. The pretreatment liquid was prepared by diluting PREGEN PCC, a pigment pretreatment liquid from Epson Como Printing Technologies Srl, 10 times with pure water. The pretreatment liquid was then uniformly applied to the substrate N1 using a bar coater, and the substrate was then dried at 100°C for 10 minutes.

[0110] Thereafter, a picture of a forest with fresh green leaves was printed on the pretreated surface of Fabric N1 using a Seiko Epson ML-8000 textile inkjet printer. Fabric N1 was then dried at 160°C for 3 minutes to obtain Fabric N1 with a colored surface of the base layer L1b.

[0111] Next, in the deposition step S5, the mixture was deposited in the air on the surface of the adhesive layer L1a of the fabric N1 to form a web W. At this time, the basis weight of the second layer L2 was 130 g / m2 The amount of the mixture deposited was adjusted so that

[0112] Next, the attaching step S6 for the three-layer structure was omitted, and the forming step S7 was carried out. In the forming step S7, the web W and fabric N1 were subjected to a heat press. An AF-54TEN (product name) from Itsumi Corporation was used as the heat press, and the heating conditions were 150°C for 1 minute, with pressure applied so that the thickness of the second layer L2 of the fabric F0 was 0.31 mm. In Example 1, the second layer L2 was not surface-treated. Then, in the cutting step S8, the fabric F0 of Example 1 was cut into single sheets measuring 250 mm in length and 100 mm in width using a cutter.

[0113] In Example 2, fabric F0 was produced in the same manner as in Example 1.

[0114] In Example 3, the fabric C used as the raw material for the second layer L2 was changed from that of Example 1. Specifically, a blue cotton fabric dyed with a dye was used as the fabric C. That is, while the second layer L2 in Example 1 was white, the second layer L2 in Example 3 was blue. The fabric F0 of Example 3 was produced in the same manner as Example 1 except for the above.

[0115] In Example 4, the fabric C used as the raw material for the second layer L2 was changed from that of Example 3. Specifically, a red cotton fabric dyed with a dye was used as the fabric C. That is, while the second layer L2 in Example 3 was blue, the second layer L2 in Example 4 was red. The fabric F0 of Example 4 was produced in the same manner as Example 1 except for the above.

[0116] In Example 5, the basis weight of the second layer L2 was 100 g / m 2 The amount of the mixture deposited was adjusted so that the fabric F0 of Example 5 was produced in the same manner as in Example 1 except for the above.

[0117] In Example 6, a three-layer structure was applied to the two-layer structure of Example 1. Specifically, the stacking step S5 was performed in the same manner as in Example 1, followed by the attachment step S6. Specifically, the fabric N1 for the first layer L1 used in Example 1 was used as the fabric N2 for the third layer L3, resulting in a three-layer structure. Therefore, the surface of the base layer L1b of the first layer L1 and the surface of the base layer L3b of the third layer L3 were colored. The fabric F0 of Example 6 was produced in the same manner as Example 1, except for the above.

[0118] In Comparative Example 1, fabric F0 was produced in the same manner as in Example 1.

[0119] In Comparative Example 2, fabric F0 was produced in the same manner as in Example 3.

[0120] In Comparative Examples 3, 4, and 5, fabric F0 was produced in the same manner as in Example 6.

[0121] 3.2. Evaluation of peelability during removal process For each fabric F0 in the Examples and Comparative Examples, the ease of peeling between the second layer L2 and other layers in the removal step S1 was evaluated to evaluate peelability. Specifically, each fabric F0 was subjected to one of the following peeling methods 1 to 3 and evaluated according to the following evaluation criteria. The evaluation results are shown in Figures 5 and 6. In Comparative Examples 1, 2, and 5, the removal step S1 was not performed, and the two-layer or three-layer clothing fabric F0 was used for the evaluation described below. In Comparative Example 3, the removal step S1 was performed only on the third layer L3 of the three-layer structure, leaving the first layer L1 and the second layer L2 as an integral part. In Comparative Example 4, the removal step S1 was performed only on the first layer L1 of the three-layer structure, leaving the third layer L3 and the second layer L2 as an integral part.

[0122] Peeling method 1: The edge of the base layer L1b was scratched with a fingernail, and the first layer L1 and the second layer L2 were peeled off from the edge. 2: The surface of the base layer L1b was heated with a dryer for 2 minutes, and then the first layer L1 and the second layer L2 were peeled off from the edge. In the fabrics F0 of Comparative Examples 5 and 6, the surface of the layer to be peeled off was heated in the same manner as above and peeled off. 3: After the surface of the base layer L1b was heated for 2 minutes with a dryer, the first layer L1 and the second layer L2 were peeled off from the edge. Next, the surface of the base layer L3b was heated for 2 minutes with a dryer, and the third layer L3 and the second layer L2 were peeled off from the edge.

[0123] Evaluation criteria A: Interfacial peeling occurred between the second layer L2 and another layer. B: No cohesive failure occurred in the second layer L2, but cohesive failure occurred in the other layers, and small amounts of the first layer L1 and part of the third layer L3 remained in the second layer L2. C: Cohesive failure occurred in the second layer L2. Alternatively, cohesive failure in other layers was significant, with most of the first layer L1 and third layer L3 remaining in the second layer L2.

[0124] 3.3. Manufacturing of clothing fabric from recycled fabrics New clothing fabric F1 was produced using the second layer L2 separated above, the fabric F0 as it was, and the second layer L2 with other layers remaining. Specifically, in the removal step S1, both the level evaluated above and the level where all or part of the peeling was omitted started production from the raw material supply step S2. In the examples and comparative examples, clothing fabric F1 was produced by reapplying the method used to produce fabric F0. In the following description, the newly produced clothing fabric F1 will also be simply referred to as fabric F1.

[0125] 3.4. Color evaluation The color of the second layer L2 of each fabric F1 in the Examples and Comparative Examples was evaluated. Specifically, the color of the second layer L2 of fabric F1 was visually compared with the color of fabric C used for the second layer L2 of fabric F0, and evaluated according to the following evaluation criteria. The evaluation results are shown in Figures 5 and 6. The color of fabric C refers to the color of the fibers used in fabric C.

[0126] Evaluation criteria A: The colors of both appear to be the same. C: There is a difference in the color of both, and they do not appear to be the same color.

[0127] 3.5.Evaluation of design Garments were made from each of the fabrics F1 of the Examples and Comparative Examples, and a sensory evaluation was conducted on the design of each level of the garments. Specifically, the designs of the garments made were evaluated according to the following evaluation criteria. The evaluation results are shown in Figures 5 and 6.

[0128] Evaluation criteria A: The color of the fabric and the printed image are exactly as the designer intended. C: The color of the fabric or the printed image is not what the designer intended.

[0129] 3.6. Summary of evaluation results As shown in Figure 5, in the evaluation of peelability, all Examples were rated B or higher, which corresponds to "pass." In particular, Examples other than Examples 1 and 3 were rated A, which corresponds to "good," indicating that the recycled clothing fabric F0 has excellent peelability. In the evaluation of color, all Examples were rated A, which corresponds to "good," indicating that the second layer L2 of the new clothing fabric F1 maintains the color of the raw material fabric C. In the evaluation of design, all Examples were rated A, which corresponds to "good," indicating that there was no change in the color of the second layer L2, improving design and its freedom of design.

[0130] On the other hand, in the evaluation of the releasability of the comparative examples, it was confirmed that the comparative examples 3 and 4 had good releasability similar to the examples.

[0131] In the color evaluation of the comparative examples, all levels were rated C, which corresponds to "unacceptable." In comparative examples 1, 2, and 5, layers other than the second layer L2 were reused without being removed, so the printed color of the other layers was mixed in. In comparative examples 3 and 4, one layer was left in the second layer L2 and reused, so the printed color of the remaining layer was mixed in.

[0132] In the evaluation of the design of the comparative example, it was rated C, which corresponds to "unacceptable," at all levels, and it was found that the color of the second layer L2 has an impact on the design. [Explanation of symbols]

[0133] F…clothing fabric, L1…1st layer, L2…2nd layer, L3…3rd layer, N1, N2…fabric, S1…removal process, S3…detangling process, S4…mixing process, S5…stacking process, S6…attaching process, S7…molding process, S11…coloring process, W…weave.

Claims

1. a removing step of removing the first layer from a used clothing fabric having a multi-layer structure including a first layer and a second layer containing fibers; a defibration step of dry-defibrating the second layer to extract the fibers; a mixing step of mixing a treatment agent with the fibers to form a colorant-free mixture; a depositing step of depositing the mixture in air onto a breathable fabric that will become a new first layer to form a web that will become a new second layer; and a molding step of molding the fabric and the web by applying pressure and heat.

2. 2. The method for manufacturing a fabric for clothing according to claim 1, wherein the fibers are white fibers.

3. 2. The method for manufacturing a fabric for clothing according to claim 1, further comprising a step of attaching a fabric to be a third layer to the surface of the web after the depositing step and before the shaping step.

4. 2. The method for manufacturing a fabric for clothing according to claim 1, further comprising a coloring step of coloring the fabric to be the new first layer with a pigment ink before the depositing step.

5. 5. The method for manufacturing a fabric for clothing according to claim 4, further comprising a pretreatment step of pretreating the fabric to be the new first layer before the coloring step.

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