Manufacturing method of woven fabric having pattern holes, hole opening processor, and woven fabric

Abstract

To provide a method for manufacturing a woven fabric having pattern holes to form an unprecedented new pattern on the woven fabric, and also to provide a fabric hole opening processor and a woven fabric.SOLUTION: A method for manufacturing a woven fabric having a plurality of pattern holes 4 includes: a woven fabric forming step to form a woven fabric 1 by weaving warp 2 and weft 3; a yarn fixing step to fix the warp 2 and the weft 3 of the woven fabric 1 by hardening of a heat fusing material; a fusing step to fuse the heat fusing material hardened by heating a prescribed part of the woven fabric 1 on which the warp 2 and the weft 3 are fixed by the yarn fixing step; a pattern hole forming step to form the pattern holes 4 by using adequate means to open a texture of a part where the heat fusing material is fused by the fusing step; and a hole edge fixing step to fix the warp 2 and the weft 3 of a hole edge 4' of the pattern hole 4 by re-hardening of the fused heat fusing material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a woven fabric having patterned holes, a hole punching machine, and the woven fabric. [Background technology]

[0002] The present applicant has focused on adhesive threads (thermal adhesive threads) that are used to prevent fraying, prevent thread loss, and function as hemming tape, and has proposed a method of forming a woven pattern, as disclosed in Patent Document 1, in which the adhesive threads are used to break up the weave in a regular or irregular manner, and then the weave is fixed by the adhesive function of the adhesive threads, thereby forming a woven pattern on the fabric.

[0003] This method of forming a weave pattern involves manually or mechanically pulling a woven fabric containing adhesive threads, for example, horizontally relative to the warp threads, causing the warp threads to snake in a regular, continuous S-shape, making the warp threads regularly sparse or dense, thereby causing the weft threads to also snake in a regular, sparse or dense pattern, thereby deforming the weave; heat is then applied to the fabric in a disrupted weave state caused by making the warp and weft threads snake in an S-shape, and the adhesive function of the adhesive threads bonds and fixes the weave, resulting in a woven fabric with an extremely lightweight weave pattern and a low weave density. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 3667653 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention provides a method for manufacturing a woven fabric having pattern holes, a woven fabric hole punching machine, and a woven fabric, which combine the techniques of the above-mentioned woven pattern forming method with a new technique to form a new pattern that has never been seen before on the woven fabric. [Means for solving the problem]

[0006] The gist of the present invention will be explained with reference to the accompanying drawings.

[0007] This method for manufacturing a woven fabric having a plurality of pattern holes 4 includes a fabric forming step of weaving warp threads 2 and weft threads 3 to form a woven fabric 1; a thread fixing step of fixing the warp threads 2 and weft threads 3 of the fabric 1 by hardening a thermal adhesive; a melting step of heating a predetermined portion of the woven fabric 1 to which the warp threads 2 and the weft threads 3 have been fixed by the thread fixing step to melt the hardened thermal adhesive; a pattern hole forming step of expanding the weave of the portion where the thermal adhesive material has melted by the melting step by an appropriate means to form the pattern holes 4; and a hole edge fixing step of fixing the warp threads 2 and the weft threads 3 at the hole edge 4' of the pattern hole 4 by re-hardening the melted thermal adhesive material.

[0008] The present invention also relates to a method for manufacturing a woven fabric having pattern holes, characterized in that the weaving yarn to which the thermal adhesive material is applied is used as the warp yarn 2 or the weft yarn 3 to weave the woven fabric 1, in the method for manufacturing a woven fabric having pattern holes as described in claim 1.

[0009] In addition, the method for manufacturing a woven fabric having a pattern hole described in claim 2 relates to a method for manufacturing a woven fabric having a pattern hole, characterized in that the woven fabric 1 is woven using a weaving yarn twisted with a thermal fusion yarn made from the thermal fusion material in thread form as the warp thread 2 or the weft thread 3.

[0010] In addition, the present invention relates to a method for manufacturing a woven fabric having pattern holes, as described in claim 3, characterized in that the weaving yarn twisted with the thermally fused yarn is used as the weft yarn 3 to weave the woven fabric 1.

[0011] In addition, the method for manufacturing a woven fabric having pattern holes described in claim 4 relates to a method for manufacturing a woven fabric having pattern holes, characterized in that the woven fabric 1 is woven using weaving yarns that do not have the thermal adhesive material and weaving yarns that have been twisted with the thermal adhesive yarns as the weft yarns 3.

[0012] The present invention also relates to a method for manufacturing a woven fabric having pattern holes, characterized in that the method for manufacturing a woven fabric having pattern holes described in claim 1 comprises using a thermally fused yarn made from the thermally fused material in thread form as a weaving yarn and employing it as the warp yarn 2 or the weft yarn 3 to weave the fabric 1.

[0013] The present invention also relates to a method for manufacturing a woven fabric having pattern holes, as described in any one of claims 1 to 6, characterized in that the spreading is carried out by inserting a sharp-tipped rod body 11 into the woven fabric and spreading the woven fabric.

[0014] The present invention also relates to a method for manufacturing a woven fabric having patterned holes, as set forth in claim 7, wherein the pointed-tip rod 11 is a heating rod.

[0015] The present invention also relates to a hole punching machine that forms a plurality of pattern holes 4 in a fabric 1 made by weaving warp threads 2 and weft threads 3 and fixing the warp threads 2 and weft threads 3 with a heat-sealing material, characterized in that the hole punching machine is equipped with a sharp-tipped rod body 11 with a heat-generating function, and the sharp-tipped rod body 11 is configured to be able to penetrate the weave of the fabric 1 and expand the weave.

[0016] The present invention also relates to a hole-punching machine as set forth in claim 9, characterized in that at least the tip of the sharp-tip rod body 11 is treated with a fluororesin.

[0017] The present invention also relates to a woven fabric having a plurality of pattern holes 4, characterized in that the pattern holes 4 are formed by a hole punching machine 10 described in any one of claims 8 and 9.

[0018] The woven fabric according to claim 11 is characterized in that the diameter of the pattern holes 4 is about several mm to several tens of mm. [Effects of the Invention]

[0019] As described above, the present invention provides a method for manufacturing a woven fabric having pattern holes, a hole punching machine, and a woven fabric, which are capable of forming new patterns never before seen on a woven fabric. [Brief explanation of the drawings]

[0020] [Figure 1] 10A to 10C are explanatory diagrams showing a pattern hole forming process in this embodiment. [Figure 2] FIG. 2 is a schematic diagram showing a hole punching machine used in the present embodiment. [Figure 3] 10A and 10B are detailed explanatory views showing a process for forming patterned holes (small diameter holes) using a hole punching machine in this embodiment. [Figure 4] 10A and 10B are detailed explanatory views showing the process of forming patterned holes (large diameter holes) using a hole punching machine in this embodiment. [Figure 5] 10A and 10B are explanatory diagrams showing patterns formed by pattern holes formed in this embodiment. [Figure 6] 10 is a photograph showing patterned holes formed by this example. [Figure 7] FIG. 7 is an enlarged explanatory view of part A in FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0021] A preferred embodiment of the present invention will be briefly described below, illustrating the operation of the present invention with reference to the drawings.

[0022] A plurality of pattern holes 4 are formed in a woven fabric 1 in which warp threads 2 and weft threads 3 are fixed by hardening a thermal adhesive. The pattern holes 4 are not formed by removing (cutting) the woven fabric 1, but by expanding the weave of the woven fabric 1 (for example, by pushing the weave open).

[0023] Specifically, the part of the woven fabric 1 where the pattern hole 4 is to be opened (formed) is heated to melt the hardened heat-sealing material, and while the heat-sealing material is in its melted state, the weave is expanded (pushed open) using an appropriate means to form the pattern hole 4, and then the warp threads 2 and weft threads 3 at the hole edge 4' of the pattern hole 4 are fixed by, for example, re-hardening the heat-sealing material by lowering the temperature.

[0024] As a result, pattern holes 4 are formed in the fabric 1, the shape of which is maintained.

[0025] The above process is repeated to form a plurality of pattern holes 4 at appropriate positions on the fabric 1.

[0026] In this way, the manufacturing method of the fabric having pattern holes 4 of the present invention makes it possible to easily form pattern holes 4 with unprecedented new patterns 5 in a lightweight woven fabric 1 with a low weaving density, and moreover, since the pattern holes 4 do not involve cutting the woven fabric 1 (warp threads 2 and weft threads 3), no fraying of threads due to cutting occurs at the hole edges 4' of the pattern holes 4, and the hole shape is stably maintained. [Example]

[0027] Specific embodiments of the present invention will be described with reference to the drawings.

[0028] This embodiment is a method for manufacturing a woven fabric having a plurality of pattern holes 4, and includes a fabric formation process in which warp threads 2 and weft threads 3 are woven to form a woven fabric 1; a thread fixing process in which the warp threads 2 and weft threads 3 of the fabric 1 are fixed by hardening a thermal adhesive; a melting process in which a predetermined portion of the fabric 1 to which the warp threads 2 and the weft threads 3 have been fixed by the thread fixing process is heated to melt the hardened thermal adhesive; a pattern hole formation process in which the weave of the portion where the thermal adhesive material has melted by the melting process is expanded by an appropriate means to form the pattern holes 4; and a hole edge fixing process in which the warp threads 2 and the weft threads 3 at the hole edge 4' of the pattern hole 4 are fixed by re-hardening the melted thermal adhesive material.

[0029] Hereinafter, each step of the manufacturing method of the woven fabric having the pattern holes 4 of this embodiment will be described in order of operation. Note that this embodiment will describe the case of manufacturing a silk woven fabric using silk thread as the weaving thread, but this embodiment can also be applied to fabrics other than silk woven fabrics.

[0030] First, warp threads 2 and weft threads 3 are woven to form a fabric 1 (fabric formation step).

[0031] In this example, in weaving the fabric 1, silk yarn is used for the warp yarn 2, and silk yarn and twisted yarn made by combining heat-sealed yarn made by combining heat-sealed material and silk yarn for the weft yarn 3 are used in combination. That is, in this example, the fabric 1 is woven using two types of yarn for the weft yarn 3: yarn with adhesive properties and yarn without adhesive properties (if twisted yarn is used for the warp yarn 2, the weft yarn 3 is likely to get caught when passing through the warp yarn 2, preventing the fabric 1 from being woven smoothly, so it is preferable to use twisted yarn for the weft yarn 3 as in this example).

[0032] Specifically, the twisted yarn used in this example is a twisted yarn obtained by twisting silk yarn (3 1 / 8 pieces) and heat-sealing yarn (50d) with a right twist for 250 turns.

[0033] The weft threads 3 are mainly silk threads with twisted yarns used in an appropriate ratio. In this example, the ratio of silk threads to twisted yarns is 2:1. In other words, the weft threads 3 in the woven fabric 1 are arranged with twisted yarns for every two silk threads. Note that the structure of the twisted yarns and the ratio with the other weaving yarns are not limited to those in this example.

[0034] Next, the woven fabric 1 is heat-treated to melt the heat-fusible yarns (heat-fusible material) in the weft yarns 3 (twisted yarns) and spread the heat-fusible material throughout the fabric 1. After that, the temperature is lowered to harden the heat-fusible material, and the warp yarns 2 and weft yarns 3 are fixed with this heat-fusible material (thread fixing process). This makes it possible to make the woven fabric 1 wearable while maintaining a low weave density. The temperature can be lowered to harden the heat-fusible material by any suitable means, such as leaving it to cool naturally or by forced cooling using cold air.

[0035] Next, a plurality of pattern holes 4 for forming a pattern 5 are formed in the fabric 1 at appropriate positions.

[0036] 1, in forming pattern holes 4 in the woven fabric 1, the portion of the woven fabric 1 where the pattern holes 4 are to be opened is heated to melt the hardened heat-fusible material (melting step), the weave patterns of the portion where the heat-fusible material has melted are expanded by an appropriate means to form the pattern holes 4 (pattern hole forming step), and then the temperature drops to re-harden the heat-fusible material, thereby fixing the warp threads 2 and weft threads 3 at the hole edge 4' of the pattern hole 4 (hole edge fixing step). That is, in this embodiment, when forming the pattern holes 4 in the woven fabric 1, the woven fabric 1 is not removed (cut out) but is expanded (the weave patterns are pushed apart) to form the pattern holes 4.

[0037] In this embodiment, as described above, the melting process and the pattern hole forming process are carried out simultaneously (the weave is expanded while the thermal adhesive material is melted), but it is of course also possible to carry out the melting process first and then the pattern hole forming process.

[0038] In this embodiment, a hole punching machine 10 is used to form the pattern holes 4.

[0039] The hole punching machine 10 used in this embodiment is equipped with a sharp-tipped rod 11, and is configured to form pattern holes 4 in the fabric 1 by inserting this sharp-tipped rod 11 into the fabric 1 and expanding (pushing open) the weave of the fabric 1.

[0040] Specifically, as shown in Figure 2, the hole punching machine 10 of this embodiment comprises a base 12 on which the woven fabric 1 is placed, a hole punching mechanism unit 13 equipped with a sharp-tipped rod 11 for punching pattern holes 4 in the woven fabric 1 set on this base 12, and an operating unit 14 for operating the sharp-tipped rod 11 of the hole punching mechanism unit 13, and is configured so that by operating the operating unit 14, the sharp-tipped rod 11 moves downward, and this sharp-tipped rod 11 penetrates the woven fabric 1 set directly below, expanding the weave and forming pattern holes 4.

[0041] More specifically, the base 12 is configured in the shape of a desk having a mounting plate 12a on which the fabric 1 is placed, and the mounting plate 12a is provided with an insertion hole 12b directly below the sharp-tipped rod 11 of the hole-punching mechanism 13 provided on the mounting plate 12a, into which the sharp-tipped rod 11 can be inserted, and when punching holes, the part for punching pattern holes 4 in the fabric 1 is set on this insertion hole 12b.

[0042] In addition, the sharp-tip rod body 11 of the hole-punching mechanism unit 13 has a tapered sharp-tip portion 11a at the tip end, and is configured to move up and down by operating the operating unit 14, and by moving downwards it is configured to pierce the fabric 1 set directly below and expand the weave of the fabric 1.

[0043] Specifically, the sharp-tip rod 11 is made of metal (stainless steel or the like), and at least the sharp-tip portion 11a is configured as a heating element having a heat generating function.

[0044] That is, as described above, in this embodiment, the fabric 1 in which the pattern holes 4 are formed has the warp threads 2 and weft threads 3 fixed by a heat-sealing material, and therefore, when forming the pattern holes 4, it is necessary to melt this heat-sealing material and make the warp threads 2 and weft threads 3 movable (released from their fixed state). The hole punching machine 10 of this embodiment is configured so that the heated sharp tip portion 11a is brought into contact with the fabric 1 and heated to melt the hardened heat-sealing material (heat-sealing thread) in the fabric 1, thereby releasing the fixed state of the warp threads 2 and weft threads 3 and enabling the sharp tip rod body 11 (sharp tip portion 11a) to be inserted into the fabric 1.

[0045] In addition, the hole-punching machine 10 of this embodiment is configured such that the sharp tip portion 11a of the sharp-tip rod body 11 is coated with a fluororesin, and the effect of this fluororesin coating is to reduce as much as possible the frictional resistance that occurs between the sharp tip portion 11a and the fabric 1 when the rod is inserted into the fabric 1, thereby preventing as much as possible damage to the fabric 1 due to friction.

[0046] As shown in the figure, the operating unit 14 is configured to be operated by stepping on it with the foot, and the hole-punching machine 10 of this embodiment is configured so that when the operating unit 14 is stepped on with the foot, the hole-punching mechanism unit 13 is activated via the wire 16 connected to the operating unit 14, and the sharp-tip rod body 11 moves downward by the amount of depression of the operating unit 14, and when the depression operation is released, the sharp-tip rod body 11 automatically moves upward.

[0047] Therefore, in the punching machine 10 of this embodiment, the penetration amount of the pointed tip rod body 11 into the fabric 1 can be adjusted by adjusting the depression amount of this operating part 14.

[0048] In this embodiment, in order to stabilize the adjustment of the penetration amount of the sharp-tip rod body 11 into the fabric 1, a penetration amount limiting member 15 is used to limit the penetration amount of the sharp-tip portion 11a into the fabric 1.

[0049] This insertion amount regulating member 15 is configured as a flat metal plate with an appropriate sized through hole 15a, the size of this through hole 15a is set smaller than the maximum diameter of the sharp tip portion 11a of the sharp tip rod body 11 (the through hole 15a is set to a size that the sharp tip portion 11a cannot penetrate), and the sharp tip portion 11a abuts against the edge of this through hole 15a to regulate (suppress) further downward movement, thereby regulating the amount of insertion of the sharp tip portion 11a into the fabric 1 and forming a hole 4 of a predetermined size in the fabric 1.

[0050] That is, in this embodiment, a hole drilling machine 10 and an insertion amount control member 15 having an appropriate size of through hole 15a selected from a plurality of insertion amount control members 15 having different sizes of through hole 15a are used (for example, when forming a small diameter pattern hole 4, an insertion amount control member 15 having a small diameter through hole 15a is used (see Figure 3), and when forming a large diameter pattern hole 4, an insertion amount control member 15 having a large diameter through hole 15a is used (see Figure 4)), and this insertion amount control member 15 controls (adjusts) the insertion amount of the sharp tip portion 11a into the fabric 1, thereby arranging and forming a plurality of pattern holes 4 having different sizes of diameters of several mm to several tens of mm (the pattern holes 4 forming the pattern 5 in the figure are about 3 mm to 8 mm) in a specified part of the fabric 1 according to the design.

[0051] After forming a plurality of pattern holes 4 of appropriate sizes in this manner, the melted thermal adhesive material is re-hardened by lowering the temperature by appropriate means such as natural cooling by leaving it to stand or forced cooling using cold air, etc., and the warp threads 2 and weft threads 3 located at the hole edge 4' of the pattern hole 4 that have moved due to expansion by the sharp tip portion 11a are fixed in that state, thereby maintaining the shape of the pattern hole 4.

[0052] As described above, in this embodiment, a plurality of pattern holes 4 forming a new, unprecedented pattern 5 as shown in Figures 5 to 7 can be easily formed in a lightweight woven fabric 1 with a low weaving density, and further, since the pattern holes 4 forming the pattern 5 do not involve cutting the woven fabric 1 (warp threads 2 and weft threads 3), no fraying of the threads due to cutting occurs at the hole edges 4' of the pattern holes 4, and the hole shape is stably maintained.

[0053] Furthermore, the fabric obtained in this example is highly breathable, light, and soft, and therefore can be used not only for summer kimonos, but also for outer fabrics of lined kimonos, kimono fabrics, obi belts, stoles, etc.

[0054] The present invention is not limited to the present embodiment, and the specific configuration of each component can be designed as appropriate. [Explanation of symbols]

[0055] 1 woven fabric 2 Warp threads 3 Weft 4 Pattern holes 4' hole rim 10. Hole punching machine 11 Sharp-tipped rod

Claims

1. A method for manufacturing a woven fabric having a plurality of pattern holes, comprising: a fabric forming step of weaving warp threads and weft threads to form a fabric; a thread fixing step of fixing the warp threads and weft threads of the fabric by hardening a thermal adhesive; a melting step of heating a predetermined portion of the fabric to which the warp threads and weft threads have been fixed by the thread fixing step to melt the hardened thermal adhesive; a pattern hole forming step of expanding the weave of the portion where the thermal adhesive material has melted by the melting step by an appropriate means to form the pattern holes; and a hole edge fixing step of fixing the warp threads and weft threads at the hole edges of the pattern holes by re-hardening the melted thermal adhesive material.

2. 2. The method for manufacturing a woven fabric having patterned holes according to claim 1, wherein the fabric is woven by using the weaving yarns to which the thermal adhesive material has been applied as the warp yarns or the weft yarns.

3. 3. The method for manufacturing a woven fabric having a pattern hole according to claim 2, wherein the fabric is woven using a weaving yarn twisted with a thermal fusion yarn made of the thermal fusion material in a thread form as the warp or weft.

4. 4. The method for producing a woven fabric having patterned holes according to claim 3, wherein the fabric is woven using weft yarns twisted with the thermal adhesive yarn.

5. 5. The method for manufacturing a woven fabric having a pattern hole according to claim 4, wherein the fabric is woven using weaving yarns to which the thermal adhesive material is not applied and weaving yarns twisted with the thermal adhesive yarn as the weft yarns.

6. 2. The method for manufacturing a woven fabric having a pattern hole according to claim 1, wherein the thermal adhesive material is formed into a thread-like thermal adhesive yarn, which is used as a weaving yarn and is employed as the warp yarn or the weft yarn to weave the fabric.

7. 7. The method for manufacturing a woven fabric having patterned holes according to claim 1, wherein the spreading is carried out by inserting a sharp-tipped rod into the woven fabric to spread the woven fabric.

8. 8. A method for manufacturing a woven fabric having patterned holes according to claim 7, wherein the pointed rod is a heating rod.

9. A hole punching machine for forming a plurality of pattern holes in a woven fabric made by weaving warp threads and weft threads and fixing the warp threads and weft threads with a heat-sealing material, the hole punching machine being characterized by having a sharp-tipped rod body with a heat-generating function, and the sharp-tipped rod body being configured to be able to penetrate the weave of the woven fabric and expand the weave.

10. 10. The drilling machine according to claim 9, wherein at least the tip of said sharp-tipped rod is coated with a fluororesin.

11. A woven fabric having a plurality of pattern holes, the pattern holes being formed by the hole punching machine according to any one of claims 8 and 9.

12. 12. The woven fabric according to claim 11, wherein the diameter of the pattern holes is about several mm to several tens of mm.

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