Manufacturing method for mesh sheet with excellent stain resistance for construction work
A ramie weave mesh sheet with heat-fusible and non-heat-fusible yarns integrated through heat treatment addresses dirt penetration and cleaning difficulties, achieving stain resistance and flexibility for construction use.
Patent Information
- Application Number
- JP2025150318
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-09-10
- Publication Date
- 2025-11-14
AI Technical Summary
Existing mesh sheets for construction work are prone to dirt penetration and difficult to clean due to their weave structure, and existing stain-resistant fabrics are not flexible enough for repeated use.
A method involving a ramie weave with heat-fusible multifilament yarns and non-heat-fusible multifilament yarns, where the heat-fusible yarns are integrated through a heat treatment process to create a mesh fabric with a georgette weave, preventing dirt penetration and ensuring flexibility.
The resulting mesh sheet exhibits excellent stain resistance, reduced dirt adhesion, and ease of cleaning, while maintaining flexibility for repeated use.
Smart Images
Figure 2025170082000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a method for producing a mesh sheet for construction work (hereinafter simply referred to as "mesh sheet") that has excellent antifouling properties. [Background technology]
[0002] Mesh fabrics with a ramie weave woven with polyethylene terephthalate multifilament yarns, which have good weather resistance, have been used as mesh sheets (Patent Document 1). Mesh fabrics with a ramie weave are less likely to become distorted and have good ventilation, making them suitable for use as mesh sheets.
[0003] Mesh sheets are reused repeatedly at various construction sites and are therefore primarily available as rental or leased products. Therefore, there is a demand for mesh sheets that are stain-resistant, easy to clean, and easy to wash. However, the mesh sheet described in Patent Document 1 is woven with multifilament yarns formed by bundling monofilaments, which has the drawback that dirt easily gets into the spaces between the monofilaments and is difficult to remove.
[0004] On the other hand, Patent Document 2 describes an invention (hereinafter referred to as the "prior invention") in which a heat-fused multifilament yarn formed by fusion bonding single filaments is used as the constituent yarn of the fabric to obtain a stain-resistant fabric. That is, this prior invention is a stain-resistant fabric composed of a heat-fused multifilament yarn formed by integrating core-sheath composite filaments, the core component of which is made of a high-melting point polymer and the sheath component of which is made of a low-melting point polymer, by melting and solidifying the sheath component.
[0005] [Patent Document 1] Japanese Patent Application Publication No. 8-109541 [Patent Document 2] Patent No. 5814045 Summary of the Invention [Problem to be solved by the invention]
[0006] An object of the present invention is to provide an example of a method for producing the stain-resistant fabric according to the above-mentioned prior invention, and to provide a method for producing a mesh sheet that is flexible and easy to wash. [Means for solving the problem]
[0007] The present invention solves the above-mentioned problems by adopting a heat-fusible multifilament yarn as a specific yarn in a ramie weave. That is, the present invention is a method for manufacturing a sheet for construction work, comprising the steps of: preparing a heat-fusible multifilament yarn formed of a group of core-sheath composite filaments whose core component is a polyethylene terephthalate-based polymer and whose sheath component is a copolymer polyester having a melting point lower than that of the polyethylene terephthalate-based polymer; preparing a non-heat-fusible multifilament yarn formed of a group of single-phase filaments made of a polyethylene terephthalate-based polymer; weaving a ramie weave fabric using the heat-fusible multifilament yarn and the non-heat-fusible multifilament yarn; and heat-treating the ramie weave fabric to obtain a mesh fabric, The present invention relates to a method for manufacturing a sheet for construction work having excellent stain resistance, characterized in that in the heat treatment step, the weaving structure unit of the pongee weave consists of three or more wefts and two warp threads, and the intersections of the wefts and warp threads form a plain weave, the two warp threads are woven at the outlets of the three or more wefts, at least one of the three or more wefts is the heat-fusible multifilament yarn, and both of the two warp threads are the non-heat-fusible multifilament yarn, and the copolyester which is the sheath component of the core-sheath composite filaments forming the heat-fusible multifilament yarn is melted to integrate the core-sheath composite filaments with each other.
[0008] First, the heat-bondable multifilament yarn prepared in the present invention will be described. The heat-bondable multifilament yarn is formed by bundling a group of core-sheath composite filaments. The core component of the core-sheath composite filament is a polyethylene terephthalate polymer with good weather resistance, and the sheath component is a copolymer polyester having a lower melting point than the polyethylene terephthalate polymer. The melting point of the polyethylene terephthalate polymer is about 255°C, and the melting point of the copolymer polyester is about 120 to 190°C. The polyethylene terephthalate polymer and / or the copolymer polyester are each preferably flame-retardant. In particular, to prevent the risk of fire at construction sites, it is preferable to use a flame-retardant polymer. To make the polyethylene terephthalate polymer and / or the copolymer polyester flame-retardant, a flame retardant may be mixed into the polymer, or a flame-retardant compound such as a phosphorus compound may be copolymerized into the polymer molecule.
[0009] The fineness of the sheath-core composite filaments is about 5 to 15 decitex, and the number of fibers bundled when forming a heat-fusible multifilament yarn is about 30 to 200. The heat-fusible multifilament yarn is preferably a twisted yarn formed by bundling and twisting a group of sheath-core composite filaments. This is because the twisted yarn allows the core-sheath composite filaments to be in closer contact with each other, and when the sheath components are melted and integrated, the surface of the resulting heat-fusible multifilament yarn becomes smooth. When forming a twisted yarn, the bundled sheath-core composite filaments may be twisted directly to form a heat-fusible multifilament yarn, or two or more bundled sheath-core composite filaments may be twisted together to form a heat-fusible multifilament yarn. The number of twists is optional, but is about 50 to 200 times per meter.
[0010] Next, the non-thermofusible multifilament yarn prepared in the present invention will be described. The non-thermofusible multifilament yarn is formed by bundling single-phase filaments made of polyethylene terephthalate-based polymers. By using such a non-thermofusible multifilament yarn, a mesh sheet with excellent weather resistance can be obtained. The fineness of the single-phase filaments is approximately 5 to 15 decitex, and the number of bundled filaments is approximately 30 to 200. Furthermore, this non-thermofusible multifilament yarn is preferably formed by bundling and twisting the single-phase filaments to form a twisted yarn. This is because the twisted yarn allows the single-phase filaments to adhere to each other more closely, making it less susceptible to dirt penetration. When forming a twisted yarn, the bundled single-phase filaments may be twisted as they are to form a non-thermofusible multifilament yarn, or two or more bundled single-phase filaments may be twisted together to form a non-thermofusible multifilament yarn. The number of twists is optional, but is approximately 50 to 200 times per meter. In addition, it is preferable to make non-thermofusible multifilament yarns flame retardant by mixing a flame retardant into the polyethylene terephthalate polymer or by copolymerizing a flame retardant compound such as a phosphorus compound into the polyethylene terephthalate polymer molecules.
[0011] The prepared heat-fusible multifilament yarn and non-heat-fusible multifilament yarn are used to weave a pongee fabric. The pongee fabric has a weave unit consisting of three or more wefts and two warps, with a plain weave at the intersection of the wefts and warps, and two warps interwoven at the exits of three or more wefts. A specific example of a pongee fabric with three wefts is shown in Figure 1. The structure enclosed by an ellipse in Figure 1 is weave unit 1. Using this weave unit 1, a plain weave is formed at the intersection of wefts 2a, 2b, and 2c and warps 3a and 3b, and warps 3a and 3b interwoven at the exits where they do not intersect with wefts 2a, 2b, and 2c (exits in the direction of the plain weave). A pongee fabric is formed by connecting these weave units 1 horizontally and vertically. As can be seen from Figure 1, when the interwoven warp threads 3a and 3b are connected to each other, gaps 4 are created, resulting in a fabric with good breathability. In addition to fabrics with three weft threads, fabrics with five or seven weft threads are also common.
[0012] At least one of the three or more weft yarns is a heat-fusible multifilament yarn. The heat-fusible multifilament yarn is a type of yarn in which the sheath component of the core-sheath composite filaments is melted in a subsequent heat treatment step to integrate the core-sheath composite filaments. In the present invention, it is preferable that all of the three or more weft yarns are heat-fusible multifilament yarns. It is also preferable that the sheath component is melted to fuse the weft and warp yarns at their intersections in a subsequent heat treatment step. This is because a mesh fabric that is less likely to become distorted is obtained.
[0013] The woven fabric obtained in the weaving step is subjected to a heat treatment. The heat treatment is carried out at a temperature at which the copolymer polyester, which is the sheath component of the heat-fusible multifilament yarn, melts. As mentioned above, the melting point of the copolymer polyester is about 120 to 190°C, so the heat treatment may be carried out at a temperature above this melting point (specifically, about 170 to 190°C as shown in the examples). This heat treatment melts the copolymer polyester, which is the sheath component of the core-sheath composite filaments that form the heat-fusible multifilament yarn, and integrates the core-sheath composite filaments together to obtain a mesh fabric.
[0014] After the heat treatment step, the molten sheath component is allowed to cool in the usual way, and solidifies to form a mesh fabric with excellent shape stability. The mesh fabric can then be made into a mesh sheet by providing eyelets or the like at the edges, and attached to temporary structures at construction sites to prevent materials from falling, dust from scattering, wind, etc. [Effects of the Invention]
[0015] The mesh sheet obtained by the method of the present invention has a georgette weave, in which the weft yarns are made of heat-fused multifilament yarns in which the sheath components of the sheath-core composite filaments in the heat-fused multifilament yarns have melted and solidified, integrating the sheath-core filaments with each other, and the warp yarns are made of non-heat-fused multifilament yarns in which single-phase filaments are simply bundled together. Therefore, the heat-fused multifilament yarns are made of sheath-core filaments integrated with each other, making it difficult for dirt to penetrate between the sheath-core filaments. Furthermore, the non-heat-fused multifilament yarns are also sandwiched between heat-fused multifilament yarns, making it difficult for dirt to penetrate between the single-phase filaments. Therefore, the mesh sheet obtained by the method of the present invention has the effect of reducing dirt adhesion and making it easier to remove any dirt that does adhere. Furthermore, because the warp yarns are made of non-heat-fused multifilament yarns, it also has the effect of being flexible in the warp direction and easy to wash. [Example]
[0016] Example 1 [Preparing the weft] Two bundles of 192 8.7-dtex core-sheath composite filaments (core / sheath mass ratio: core = 2.7 / sheath = 1.0) were twisted together at 80 twists / m to form a twisted yarn. The flame-retardant polyethylene terephthalate polymer was prepared by copolymerizing polyethylene terephthalate with a phosphorus compound in an amount of 1% by mass or less. The core filament was a flame-retardant polyethylene terephthalate polymer (melting point: 255°C) and the sheath filament was a crystalline copolymer polyester (melting point: 160°C).
[0017] [Preparing the warp threads] The warp yarn was prepared by bundling 140 single-phase filaments with a fineness of 13 dtex made of flame-retardant polyethylene terephthalate polymer (melting point 255°C) and twisting them at a twist rate of 80 times per meter. The flame-retardant polyethylene terephthalate polymer was prepared by copolymerizing polyethylene terephthalate with a phosphorus compound in an amount of 1% by mass or less.
[0018] The prepared weft and warp yarns were woven in the weave structure shown in Figure 1 to obtain a three-strand woven fabric. This fabric was then heat-treated at 170°C for 43 seconds to obtain a mesh fabric. This mesh fabric had a warp density of 25.4 threads / inch and a weft density of 12.7 threads / inch. The sheath component of the weft yarn melted and solidified, forming a heat-fused multifilament yarn in which the core-sheath composite filaments were integrated with each other, and which was also fused to the warp yarns at their intersections.
[0019] Example 2 [Preparing the weft] A bundle of 192 core-sheath composite filaments (core / sheath mass ratio: core = 2.7 / sheath = 1.0) with a fineness of 8.7 dtex, each having a core component made of a flame-retardant polyethylene terephthalate polymer (melting point: 255°C) and a sheath component made of a crystalline copolyester (melting point: 160°C), was twisted together with a bundle of 140 polyethylene terephthalate filaments with a fineness of 7.1 dtex at a twist rate of 80 times per meter to form a twisted yarn. This twisted yarn was used as a weft. The flame-retardant polyethylene terephthalate polymer was the same as that used in Example 1. [Preparing the warp threads] The same warp yarns as those used in Example 1 were prepared.
[0020] The prepared weft and warp yarns were woven in the weave structure shown in Figure 1 to obtain a three-strand woven fabric. This fabric was then heat-treated at 170°C for 43 seconds to obtain a mesh fabric. This mesh fabric had a warp density of 25.4 threads / inch and a weft density of 14.4 threads / inch. The sheath component of the weft yarn was melted and solidified to form a heat-fused multifilament yarn in which the core-sheath composite filaments were integrated with each other and between the core-sheath composite filaments and the polyethylene terephthalate filaments, and the weft yarn was fused with the warp yarns at their intersections.
[0021] Example 3 [Preparing the weft] The weft yarn used in Example 1 was used as the first twisted yarn. A bundle of 140 polyethylene terephthalate filaments with a fineness of 13 dtex was twisted together at a twist rate of 80 times per meter to form the second twisted yarn. These first twisted yarn and second twisted yarn were prepared as the weft yarn. [Preparing the warp threads] The same warp yarns as those used in Example 1 were prepared.
[0022] The prepared weft and warp yarns were woven in the weave structure shown in Figure 1 to obtain a three-strand georgette fabric. In this case, the second twisted yarn was used as weft yarns 2a and 2c, and the first twisted yarn was used as weft yarn 2b. This fabric was heat-treated at 190°C for 43 seconds to obtain a mesh fabric. This mesh fabric had a warp density of 25.4 threads / inch and a weft density of 16.1 threads / inch. Furthermore, the sheath component of weft yarn 2b melted and solidified, forming a heat-fused multifilament yarn in which the core-sheath composite filaments were integrated with each other, and it was fused to weft yarns 2a and 2c and further fused to the warp yarns at their intersections.
[0023] Example 4 [Preparing the weft] The weft yarn used in Example 2 was used as the first twisted yarn. A bundle of 140 polyethylene terephthalate filaments with a fineness of 13 dtex was twisted together at a twist rate of 80 times per meter to form the second twisted yarn. These first twisted yarn and second twisted yarn were prepared as the weft yarn. [Preparing the warp threads] The same warp yarns as those used in Example 1 were prepared.
[0024] The prepared weft and warp yarns were woven according to the weave structure shown in Figure 1 to obtain a three-strand georgette fabric. In this case, the second twisted yarn was used as weft yarns 2a and 2c, and the first twisted yarn was used as weft yarn 2b. This fabric was heat-treated at 190°C for 43 seconds to obtain a mesh fabric. This mesh fabric had a warp density of 25.4 threads / inch and a weft density of 17.8 threads / inch. Furthermore, the sheath component of weft yarn 2b melted and solidified, forming a heat-fused multifilament yarn in which the core-sheath composite filaments were integrated with each other and with the polyethylene terephthalate filaments. The weft yarn 2b was also fused with weft yarns 2a and 2c and further fused with the warp yarns at their intersections.
[0025] Comparative Example [Preparing the weft] Two bundles of 140 polyethylene terephthalate filaments each having a fineness of 13 decitex were twisted together at a twist rate of 80 times per meter to form a twisted yarn, which was used as a weft. [Preparing the warp threads] The same warp yarns as those used in Example 1 were prepared.
[0026] The prepared weft and warp yarns were woven in the weave structure shown in Figure 1 to obtain a three-strand woven fabric. This fabric was then heat-treated at 190°C for 43 seconds to obtain a mesh fabric. This mesh fabric had a warp density of 25.4 threads / inch and a weft density of 17.8 threads / inch. The weft and warp yarns were not fused together, maintaining the original twisted yarn configuration, and the intersections of the weft and warp yarns were not fused either.
[0027] [Evaluation of antifouling properties] (1) Evaluation of stain resistance Each mesh fabric obtained in Examples 1 to 4 and the Comparative Example was cut into a 10 cm x 10 cm piece to prepare a test specimen (mass W0). This test specimen and 1.0 g of dry artificial contaminant were placed in a 28 cm x 20 cm zippered polyethylene bag, and air was then sealed inside. The artificial contaminant consisted of 55% by mass of diatomaceous earth, 22% by mass of Portland cement, 20% by mass of silicon dioxide, 2% by mass of carbon black, and 1% by mass of iron oxide for ferrite. The bag was then placed in the rotating box of an ICI pilling tester and rotated at a speed of 60 ± 2 rpm for 1 hour to perform a contamination treatment. After the contamination treatment, the test specimen was removed and its mass (W1) was measured. The amount of contaminant attached (g) was then measured using the following formula, and the results are shown in Table 1. The smaller the attached amount (g), the more resistant to soiling it was evaluated. Amount of contaminant attached (g) = W1 - W0
[0028] (2) Evaluation of ease of removing dirt After the contamination treatment, the removed test piece was re-held at each of the four corners and the center of the test piece was flicked with a finger to remove excess dirt. The flicking was performed with two fingers, and after each flick, the test piece was re-held at each of the four corners and rotated 90 degrees, for a total of five flicks. The mass (W2) of the test piece after the excess dirt had been removed was measured. The removal rate (%) of the contaminants was then calculated using the following formula, and the results are shown in Table 1. The higher the removal rate (%), the easier it was to remove the dirt. Contaminant shedding rate (%) = {[(W1-W0)-(W2-W0)] / (W1-W0)} x 100
[0029] [Table 1] ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Amount of contaminant attached (g) Contaminant removal rate (%) ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Example 1 0.197 81 Example 2 0.273 79 Example 3 0.234 71 Example 4 0.239 72 Comparative Example 0.283 52 ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
[0030] As can be seen from the results in Table 1, the mesh fabrics obtained in Examples 1 to 4 had a smaller amount of contaminant adhesion (g) and were less susceptible to soiling than the mesh fabric obtained in the Comparative Example. Furthermore, the mesh fabrics obtained in Examples 1 to 4 had a larger contaminant shedding rate (g) and were easier to remove soiling than the mesh fabric obtained in the Comparative Example. [Brief explanation of the drawings]
[0031] [Figure 1] FIG. 1 is a diagram showing a mesh fabric with a three-strand ramie weave obtained by a method according to one example of the present invention. [Explanation of symbols]
[0032] 1. Weaving unit 2a, 2b, 2c weft 3a, 3b warp threads 4. Gap
Claims
1. a step of preparing a heat-fusible multifilament yarn formed of a group of core-sheath type composite filaments, the core component of which is made of a polyethylene terephthalate-based polymer and the sheath component of which is made of a copolymer polyester having a melting point lower than that of the polyethylene terephthalate-based polymer; A step of preparing a non-thermofusible multifilament yarn formed of a group of single-phase filaments made of a polyethylene terephthalate-based polymer; a weaving step of weaving a woven fabric with a ramie weave using the heat-fusible multifilament yarn and the non-heat-fusible multifilament yarn; A method for manufacturing a sheet for construction work, comprising a heat treatment step of heat treating the woven fabric of the pongee weave to obtain a mesh fabric, In the weaving step, the weaving structure unit of the pongee weave is composed of three or more wefts and two warps, and a plain weave structure is formed at the intersection of the wefts and the warps, the two warps are woven at the outlet of the three or more wefts, at least one of the three or more wefts is the heat-fusible multifilament yarn, and both of the two warps are the non-heat-fusible multifilament yarn, A method for manufacturing a construction sheet with excellent stain resistance, characterized in that in the heat treatment process, the copolymer polyester, which is the sheath component of the core-sheath composite filaments that form the heat-fusible multifilament yarn, is melted to integrate the core-sheath composite filaments with each other.
2. 2. A method for producing a mesh sheet for construction work having excellent stain resistance according to claim 1, wherein the number of weft threads in the weaving structure unit of the pongee weave is three.
3. 3. A method for producing a mesh sheet for construction work having excellent stain resistance according to claim 2, wherein all three weft yarns are heat-fusible multifilament yarns.
4. 2. The method for producing a mesh sheet for construction work having excellent stain resistance according to claim 1, wherein the polyethylene terephthalate polymer constituting the core component and the polyethylene terephthalate polymer constituting the single-phase filaments are flame-retardant polyethylene terephthalate polymers.
5. 5. The method for producing a mesh sheet for construction work having excellent stain resistance according to claim 4, wherein the flame-retardant polyethylene terephthalate polymer is obtained by copolymerizing a phosphorus compound in the polymer molecule.