Fabric structure and manufacturing method thereof

Abstract

The present invention provides a fabric structure including a base fabric and a laminate layer. The base fabric is produced by weaving a plurality of yarns, each of which is composed of a fiber. The laminate layer is disposed on the base fabric. The fiber and the laminate layer are free of polyvinyl chloride. Also provided is a method for producing the fabric structure.

Description

[Technical Field]

[0001] The present invention relates to fabric structures and methods for making same. [Background technology]

[0002] Polyvinyl chloride (PVC) is a plastic that contains chlorine, which is why it has been called a "toxic plastic" by the international environmental organization Greenpeace. Furthermore, due to the poor stability of PVC, PVC products require the addition of environmentally harmful additives such as plasticizers, stabilizers, and / or stabilizers. For example, to prevent PVC products with poor thermal stability from decomposing under sunlight or high temperatures, stabilizers containing heavy metals such as lead, cadmium, and zinc must be added.

[0003] On the other hand, to provide waterproofing, it is common to form a laminate layer on the surface of the base fabric of a fabric. However, due to factors such as the weaving structure and material properties, the laminate layer does not adhere well to the surface of the base fabric, and the material itself has limitations (such as a lack of flexibility). Therefore, when the fabric is bent or hit, the laminate layer is very likely to break or peel off at the bent point, causing the fabric to lose its waterproofing function. Summary of the Invention

[0004] The present invention provides a fabric structure and a method for manufacturing the same that can comply with environmental protection trends while simultaneously reducing the probability of delamination of the laminate layer.

[0005] The fabric structure of the present invention includes a base fabric and a laminate layer. The base fabric is made by weaving a plurality of yarns. Each yarn is composed of a fiber. The laminate layer is disposed on the base fabric. The fiber and the laminate layer are free of polyvinyl chloride.

[0006] In one embodiment of the present invention, the fibers include polypropylene, polyethylene terephthalate, or a combination thereof.

[0007] In one embodiment of the present invention, the laminate layer includes a polymer, a flame retardant, an adjuvant, or a combination thereof.

[0008] In one embodiment of the present invention, the polymer comprises polypropylene, low density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer, polymer polyol, or a combination thereof.

[0009] In one embodiment of the present invention, the flame retardant comprises a brominated flame retardant, a halogen-free flame retardant, a metal compound flame retardant, or a combination thereof.

[0010] In one embodiment of the present invention, the additive comprises aluminum oxide hydrate, aluminum sulfate, aluminum hydroxide, silicon dioxide, or a combination thereof.

[0011] In one embodiment of the present invention, the substrate is not a sheet-like woven structure.

[0012] In one embodiment of the present invention, the base fabric is a white base fabric, a checkered base fabric or a black base fabric.

[0013] The method for producing a fabric structure of the present invention includes spinning yarns into a base fabric, each of which is composed of a fiber, and forming a laminate layer on the base fabric, wherein the fiber and the laminate layer are free of polyvinyl chloride.

[0014] In one embodiment of the present invention, the step of forming the laminate layer includes performing a granulation process to form a plurality of particles, and melting the plurality of particles to form them on the base fabric.

[0015] Based on the above, the present invention improves the knitting and weaving method of the base fabric, so that the base fabric is woven from a plurality of yarns composed of fibers, thereby effectively preventing the laminate layer provided on the base fabric from falling off, and since the base fabric fibers and the laminate layer do not contain polyvinyl chloride, an environmentally friendly fabric structure can be achieved, thereby complying with the trend of environmental protection and reducing the probability of the laminate layer peeling off.

[0016] In order to make the above features and advantages of the present invention more clearly understandable, the following examples will be given in conjunction with the accompanying drawings and will be described in detail. [Brief explanation of the drawings]

[0017] [Figure 1A] 1 is a schematic diagram of a base fabric according to an embodiment of the present invention. [Figure 1B] 1 is a schematic diagram of a fabric structure in one embodiment of the present invention. [Figure 2A.2B.2C] 1 is a schematic diagram of a prior art method for manufacturing a fabric structure. DETAILED DESCRIPTION OF THE INVENTION

[0018] Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same element symbols are used in the drawings and the description to refer to the same or like parts.

[0019] The following examples of the present invention will be described in detail, but these examples are merely illustrative and the present invention is not limited to these examples, and the present invention is defined by the claims.

[0020] Hereinafter, exemplary embodiments of the present invention will be comprehensively described with reference to the drawings. However, the present invention can be embodied in various forms and should not be construed as being limited to the embodiments described herein. In the drawings, for clarity, the size and thickness of each region, part, and layer may not be drawn to scale. For ease of understanding, the same elements will be labeled with the same reference numerals in the following description.

[0021] Directional terms used herein (e.g., up, down, right, left, front, back, top, bottom) are used solely to refer to the drawings depicted and do not imply absolute directions.

[0022] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0023] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It is also understood that terms (as defined in commonly used dictionaries) should be interpreted to have a meaning consistent with their meaning in the context of the relevant art, and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0024] In this specification, ranges expressed as "from one value to another value" are a generalization to avoid listing every single value in the range in the specification. Therefore, the description of a particular range of values ​​covers any value within that range and any smaller range defined by any value within that range, and is equivalent to writing out those any values ​​and smaller ranges in the specification.

[0025] FIG. 1A is a schematic diagram of a base fabric according to one embodiment of the present invention. FIG. 1B is a schematic diagram of a fabric structure according to one embodiment of the present invention. FIGS. 2A, 2B, and 2C are schematic diagrams of a method for manufacturing a fabric structure according to the prior art. Referring to FIGS. 1A and 1B, the fabric structure 100 of this embodiment includes a base fabric 110 and a laminate layer 120, with the laminate layer 120 disposed on the base fabric 110. Furthermore, in this embodiment, the knitting method of the base fabric 110 is improved so that the base fabric 110 is woven with a plurality of yarns 112 composed of fibers 112a. This effectively prevents the laminate layer 120 disposed on the base fabric 110 from falling off. Furthermore, since the fibers 112a of the base fabric 110 and the laminate layer 120 do not contain polyvinyl chloride (PVC), this fabric structure is environmentally friendly, thereby complying with the trend of environmental protection and reducing the probability of peeling of the laminate layer 120.

[0026] 2A, 2B, and 2C, in the prior art, a polymeric material is first rolled into a film sheet 10, then the film sheet 10 is cut into multiple sections 10a (e.g., multiple rectangular strips), and finally plain woven to form a base fabric. However, the laminate layer formed on the base fabric in this sheet-like weaving method does not have high adhesion and is prone to falling off, which can result in a loss of waterproofing. Therefore, compared to the prior art, the base fabric 110 of this embodiment has a tighter woven or knitted structure rather than a sheet-like knitted structure (the edge of the base fabric 110 has fibers 112a, as shown in the enlarged portion of FIG. 1B, indicating that it is not a sheet-like knitted structure). This effectively increases the adhesion between the laminate layer 120 and the base fabric 110 and improves the peeling phenomenon of the laminate layer 120, but the present invention is not limited to this.

[0027] In some embodiments, the fibers 112a include polypropylene (PP), polyethylene terephthalate (polyester, PET), or a combination thereof, and thus the PVC-free fabric structure 100 of this embodiment can achieve characteristics such as excellent strength and light weight while complying with environmental protection requirements, but the present invention is not limited thereto.

[0028] In some embodiments, the laminate layer 120 comprises a polymer, a flame retardant, an auxiliary, or a combination thereof, where the flame retardant can provide the fabric structure 100 with a flame retardant function, and the auxiliary can improve the whiteness or provide other functionality of the fabric structure 100. Here, the flame retardant and auxiliary are optional, i.e., whether or not to add the flame retardant and auxiliary can be selected according to actual design needs.

[0029] In some embodiments, the polymer content is between 50 wt% (weight percent) and 100 wt% (e.g., 50 wt%, 60 wt%, 70 wt%, 80 wt%, 90 wt%, 100 wt%, or any number between 50 wt% and 100 wt%), the flame retardant content is between 0 wt% and 20 wt% (e.g., 0 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or any number between 0 wt% and 20 wt%), and the coagent content is between 0 wt% and 1 wt% (e.g., 0 wt%, 0.2 wt%, 0.4 wt%, 0.6 wt%, 0.8 wt%, 1 wt%, or any number between 0 wt% and 1 wt%), but the invention is not limited thereto.

[0030] In some embodiments, the polymer of the laminate layer 120 may include polypropylene (PP), low density polyethylene (HP-LDPE), polyolefin elastomers (POE), ethylene-vinyl acetate copolymer (EVA), polymer polyol (POP), or a combination thereof. Depending on the actual design needs, the polymer may be used singly or in combination of at least two or more types, providing greater flexibility in material selection for the laminate layer 120. The relevant properties of the aforementioned polymers are further described below. However, it should be noted that these descriptions are not intended to limit the present invention, and that any polymer embodiments well known to those skilled in the art are within the scope of the present invention.

[0031] <Polypropylene>

[0032] It is a polymer produced by the addition polymerization of propylene. It is a white wax-like material that is transparent and lightweight. Its chemical formula is (C3H6)n and its density is 0.89 g / cm 3 to 0.91 g / cm 3 It is flammable, has a melting point of 189°C (softens at around 155°C), and has a usable temperature range of -30°C to 140°C. Furthermore, it can withstand corrosion by acids, alkalis, salt solutions, and many organic solvents at temperatures below 80°C, and can decompose at high temperatures and under oxidizing conditions.

[0033] <Low-density polyethylene>

[0034] It is a high-pressure, low-density polyethylene (HDLPE), a lighter type of polyethylene resin. It is milky white, tasteless, odorless, and non-toxic, with a matte, waxy surface. It has good flexibility, elongation, electrical insulation, transparency, ease of processing, and a certain degree of breathability. It also has relatively good chemical stability and is resistant to alkalis and common organic solvents.

[0035] <Polyolefin elastomer>

[0036] It is a copolymer of ethylene and octene, and the copolymerization monomer is octene (C8H 16 The content of octene can be 20%-30%. The presence of octene in the molecular structure prevents the crystallization of ethylene, but at the same time, it imparts excellent transparency and good elasticity to the copolymer. At room temperature, the ethylene crystals become physical crosslinking points, and at high temperatures, the ethylene decrystallizes, giving the copolymer plasticity. Furthermore, the narrow molecular weight distribution gives POE high tensile strength and impact resistance. Meanwhile, the branching effect of octene significantly improves the thermosensitivity of the copolymer, greatly strengthening the polymer's processability.

[0037] In some embodiments, polyolefin elastomer (POE) is a thermoplastic elastomer obtained by in-situ polymerization of ethylene and α-olefins using a metallocene catalyst. The crystalline regions of the polyethylene chains (resin phase) function as physical crosslinking points, resulting in typical plastic properties. When a certain amount of α-olefin (e.g., 1-butene, 1-hexene, 1-octene, etc.) is added, the crystalline regions of the polyethylene chains are weakened, resulting in the formation of atypical regions (rubber phase) that exhibit rubber elasticity, giving the product the properties of an elastomer. Therefore, POE has excellent comprehensive performance, possessing the dual properties of plastic and rubber, and can be considered a product that bridges the gap between plastic and rubber.

[0038] <Ethylene-vinyl acetate copolymer>

[0039] It is a general-purpose polymer with the molecular formula (C2H4) X .(C4H6O2) y (as shown in formula (1)) and is flammable, but does not produce an irritating odor when burned. EVA has better weather resistance and aging resistance than PE materials. Furthermore, the VA content can affect the properties of EVA resins. For example, when the VA content is 10%-20%, EVA is a plastic material, while when the VA content exceeds 30%, EVA becomes an elastic material. Furthermore, as the VA content increases, the resilience, flexibility, transparency, solubility, stress crack resistance, impact performance, and adhesive properties of the EVA material all improve. However, the present invention does not limit the VA content, and it can be selected based on actual design requirements. Meanwhile, because the side chain of EA is a polar group, increasing the content increases solubility, decreases chemical resistance, increases polarity, and improves adhesion and bond strength to substrates. In some embodiments, increasing the EVA content decreases the stiffness, abrasion resistance, and electrical insulation properties of the EVA.

[0040] Formula (1) JPEG2025534834000002.jpg49136

[0041] <Polyol>

[0042] Octylphenol, i.e., 4-octylphenol or 4-n- It is an octylphenol, a chemical industrial product that is widely used in the production of oil-soluble phenolic resins, surfactants, adhesives, etc.

[0043] In some embodiments, the polymer may be a mixture of two materials, such as a combination of polypropylene and low-density polyethylene, a combination of polypropylene and polyolefin elastomer, a combination of polypropylene and ethylene-vinyl acetate copolymer, or a combination of polypropylene and polyol, and the ratio of these combinations may be between 18:61 and 61:18, but the present invention is not limited thereto. The polymers and their ratios may be determined based on actual design needs.

[0044] In some embodiments, the flame retardant may include a bromine-based flame retardant, a halogen-free flame retardant, a metal compound flame retardant, or a combination thereof. For example, bromine-based flame retardants include 1,2,4,5-tetrabromo-3,6-bis(bromomethyl)benzene (1,2,4,5-TETRABROMO-3,6-BIS(BROMOMETHYL)BENZENE), bis(pentabromophenyl)ethane (DBDPE), and polybrominated diphenyl ether (PBDE). The halogen-free flame retardant may be, for example, a phosphorus-nitrogen-based halogen-free flame retardant or other suitable halogen-free flame retardant. Among these, halogen-free flame retardants include ammonium polyphosphate, melamine, expandable graphite, and melamine phosphate. The metal compound flame retardant may include diantimony trioxide, but the present invention is not limited thereto. Here, bis(pentabromophenyl)ethane is an environmentally friendly flame retardant, and the polybrominated diphenyl ether is, for example, decabromodiphenyl ether (DecaBDE).

[0045] In some embodiments, the additives may include, but are not limited to, aluminum oxide hydrate (ATH), aluminum sulfate, aluminum hydroxide, silicon dioxide, or a combination thereof. Here, the additives may be used as fillers, and aluminum sulfate, aluminum hydroxide, etc. may also be used as raw materials to achieve specific whiteness requirements.

[0046] In some embodiments, the base fabric 100 is a white base fabric, a checkered base fabric, or a black base fabric, and the base fabric structure 100 can be a woven fabric or a knitted fabric, although the present invention is not limited thereto.

[0047] In some embodiments, the fabric structure 100 is canvas and has applications in awnings, truck covers, tents, and industrial fabrics, although the invention is not limited thereto.

[0048] The main steps of the method for manufacturing a fabric structure in one embodiment of the present invention are further described below.

[0049] First, yarns are produced into a fabric by a spinning process, where each yarn is comprised of fibers, and the fibers are free of polyvinyl chloride. More specifically, a flyer and bobbin hand-operated spinning machine can be used to form a woven fabric by continuous and simultaneous drawing, twisting, and winding operations.

[0050] Next, a laminate layer is formed on the base fabric, and the process for forming the laminate layer can include a granulation process (which allows the polymer to be mixed more uniformly) to form multiple particles, and then melting the multiple particles and forming them on the base fabric. More specifically, the polymer, flame retardant, and / or auxiliary are mixed, then granulated to form multiple particles, and the granulated particles are melted at a high temperature to reach their glass transition temperature (Tg) to provide fluidity. The resulting mixture is then extruded and cast-molded using a lamination machine (e.g., extruded in a streamlined molten state through a die opening), stretched, and then the laminate material is attached to the surface of the base fabric. The laminate layer can be cooled and pressed into a fixed shape to form a laminate layer with functional properties such as barrier properties, heat sealability, and toughness, but the present invention is not limited thereto.

[0051] In some embodiments, the melting temperature is, for example, 110° C. to 200° C. (preferably about 170° C.), although the invention is not so limited and different polymers correspond to different melting temperatures.

[0052] In some embodiments, the thickness of the laminate layer can be adjusted by the machine gap during extrusion, for example, but not limited to, a thickness in the range of 0.1 to 0.2 millimeters.

[0053] Tables 1 and 2 below provide the component compositions specifically used in the above-described fabric structures of the present invention and corresponding data, and therefore the fabric structures of the present application can certainly be realized based on these, but these data are illustrative and the present invention is not limited to these examples. Here, the tensile strength and tear resistance in Tables 1 and 2 were measured using a tensile tester, and Table 2 shows the compounding ratio of the laminate layer, expressed in wt%.

[0054] Table 1 JPEG2025534834000003.jpg32145

[0055] Table 2 JPEG2025534834000004.jpg230156

[0056] As described above, the present invention improves the knitting and weaving method of the base fabric, allowing the base fabric to be woven from multiple fiber threads, thereby effectively preventing the laminate layer formed on the base fabric from falling off. Furthermore, since the base fabric fibers and laminate layer do not contain polyvinyl chloride, the fabric structure is environmentally friendly, thereby complying with the trend of environmental protection and reducing the probability of the laminate layer peeling off.

[0057] Finally, it should be noted that the above embodiments are only for illustrating the technical solutions of the present invention, and are not intended to limit the same. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the above embodiments, or equivalent substitutions can be made for some or all of the technical features thereof, and these modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A base fabric made by weaving a plurality of threads, each of the threads being composed of a fiber; a laminate layer provided on the base fabric, The fabric structure, wherein the fibers and the laminate layer are free of polyvinyl chloride.

2. 10. The fabric structure of claim 1, wherein the fibers comprise polypropylene, polyethylene terephthalate, or a combination thereof.

3. 10. The fabric structure of claim 1, wherein the laminate layer comprises a polymer, a flame retardant, an adjuvant, or a combination thereof.

4. 4. The fabric structure of claim 3, wherein the polymer comprises polypropylene, low density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer, polymer polyol, or a combination thereof.

5. 4. The fabric structure of claim 3, wherein the flame retardant comprises a brominated flame retardant, a halogen-free flame retardant, a metal compound flame retardant, or a combination thereof.

6. 4. The fabric structure of claim 3, wherein the adjuvant comprises aluminum oxide hydrate, aluminum sulfate, aluminum hydroxide, silicon dioxide, or a combination thereof.

7. 10. The fabric structure of claim 1, wherein the substrate is not a sheet-like woven structure.

8. 2. The fabric structure of claim 1, wherein the backing is a white backing, a checkered backing, or a black backing.

9. A spinning process is used to produce yarns into a base fabric, each of which is made of fiber; and A method of making a fabric structure comprising forming a laminate layer on the backing fabric, wherein the fabric and the laminate layer are free of polyvinyl chloride.

10. The step of forming the laminate layer includes: conducting a granulation step to form a plurality of particles; and The method of claim 9, further comprising melting the plurality of particles onto the backing.

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