Dough and method for producing dough

Abstract

SOLUTION: Provided is a leather-like fabric using at least one of embossed polyester, nylon, acrylic, linen, cotton, silk, rayon or wool, wherein an embossing depth of the fabric is 50 μm or more and 400 μm or less. The method for producing leather-like dough includes a step of preparing leather-like dough and a step of embossing the dough, wherein the emboss depth of the dough is ≥ 50 μm and ≤ 400 μm. The embossing of the fabric may include disposing a low-density member having a lower density than the fabric under the fabric, and embossing the fabric in a state in which the low-density member is disposed under the fabric.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a dough and a method for producing the dough. [Background technology]

[0002] Patent Document 1 discloses an embossed "leather-like nonwoven fabric." [Prior art document] [Patent documents] Patent Document 1 Japanese Patent Application Laid-Open No. 11-241277

[0003] Provides higher quality leather-like fabric. Summary of the Invention

[0004] In a first aspect of the present invention, there is provided a leather-like fabric using at least one of embossed polyester, nylon, acrylic, linen, cotton, silk, rayon, and wool, wherein the embossing depth of the fabric is 50 μm or more and 400 μm or less.

[0005] The fabric may meet at least one of the evaluation standards of JIS L1096, L1093, L1092, L1076, L0860, L0849, L0844, or L0842.

[0006] Any of the above-described leather-like fabrics may have a predetermined first contraction yarn and a second contraction yarn different from the first contraction yarn. The first contraction yarn and the second contraction yarn may be mixed.

[0007] Any of the above leather-like fabrics may have a single yarn decitex of 0.05 or more and 0.7 or less.

[0008] Any of the above leather-like fabrics may have a warp thread density of 200 or more and 300 or less.

[0009] In any of the above-described leather-like fabrics, the thickness of the fabric may be 0.3 mm or more and 1.5 mm or less.

[0010] In a second aspect of the present invention, there is provided a method for producing leather-like fabric, comprising the steps of preparing a leather-like fabric and embossing the fabric, wherein the embossing depth of the fabric is 50 μm or more and 400 μm or less.

[0011] In the above-mentioned method for manufacturing fabric, the step of embossing the fabric may include the steps of placing a low-density member that is lower in density than the fabric under the fabric, and embossing the fabric with the low-density member placed under the fabric.

[0012] In any of the above methods for manufacturing fabric, the embossing step may include a step of surface-heating the fabric using an embossing machine that uses a roll-shaped or plate-shaped mold.

[0013] The above summary of the invention does not list all of the features of the present invention, and subcombinations of these features may also be inventions. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a photograph of the surface of fabric 100. [Figure 2] 1 is a schematic diagram of a cross section of fabric 100. FIG. [Figure 3] An example of the configuration of the warp threads 10 is shown. [Figure 4] An example of textured yarn used for warp yarn 510 according to a comparative example is shown. [Figure 5] An example of a method for manufacturing the fabric 100 will be described. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention will be described below through embodiments of the invention, but the following embodiments do not limit the scope of the invention according to the claims. Furthermore, not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0016] FIG. 1 is a photograph of the surface of fabric 100. Fabric 100 is an embossed leather-like fabric made of at least one of polyester, nylon, acrylic, linen, cotton, silk, rayon, and wool. Fabric 100 may have texture and gloss like genuine leather or synthetic leather. Fabric 100 in this example achieves the embossed leather-like texture without providing a backing fabric such as a nonwoven fabric on the reverse side.

[0017] The leather-like fabric 100 made of polyester can reduce the mass by 50% or more compared to fabrics made of genuine leather or polyvinyl chloride (PVC). Furthermore, unlike fabrics made of genuine leather or PVC, the fabric 100 is less likely to become too hot in the summer or too cold in the winter. The finish of the fabric 100 can be improved by using a steam iron. The recyclability of the fabric 100 can be improved by using only polyester.

[0018] The fabric 100 may be used for vehicle seat covers that require high strength, wrinkle resistance, flame retardancy, etc. The fabric 100 may meet at least one of the evaluation standards of JIS L1096, L1093, L1092, L1076, L0860, L0849, L0844, or L0842. However, the use of the fabric 100 is not particularly limited.

[0019] FIG. 2 is a schematic diagram of a cross section of fabric 100. Fabric 100 has concaves and convexes formed by embossing. Fabric 100 of this example can achieve deep embossing without providing a backing fabric such as a nonwoven fabric on the back side. The embossing depth De of fabric 100 may be 50 μm or more and 400 μm or less. The embossing depth De may be the maximum value of the difference between the convex portions and concave portions in the embossed area.

[0020] Here, the fabric 100 may have a single yarn with a decitex of 0.05 or more and 0.7 or less. By thinning the single yarn, the rigidity of the single yarn is weakened, allowing for a deeper embossing. Furthermore, by thinning the single yarn, it is possible to eliminate stitches and achieve a high-quality leather-like fabric with improved texture.

[0021] As will be described later, the thickness of the fabric 100 can be increased by including a shrinkage thread, which gives the thread swelling. The thickness T of the fabric 100 may be 0.3 mm or more and 1.5 mm or less. The thickness T of the fabric 100 may be the thickness between the embossed convex portions and the back surface of the fabric 100.

[0022] The fabric 100 may include warp threads and weft threads. Increasing the thread density of the warp threads reduces the gaps in the fabric 100, making the weft threads less visible. This makes the fabric 100 flatter, making it easier to achieve a high-quality leather-like fabric. Thread density is the number of single threads per inch. The thread density of the warp threads may be 200 or more and 300 or less. For example, skipping five or more surface threads of the weft threads causes shrinkage in the horizontal direction, allowing the thread density of the warp threads to be increased.

[0023] Here, if the single thread of the fabric 100 is thinned, there is a risk of thread breakage due to the embossing process. In this example, by increasing the thread density of the warp threads and increasing the total number of threads, it is possible to provide a fabric 100 that is less likely to break threads, by dispersing the embossing pressure, even when the single thread of the fabric 100 is thinned.

[0024] FIG. 3 shows an example of the configuration of the warp yarns 10. The warp yarns 10 of this example have a predetermined first shrinkage yarn 11 and a second shrinkage yarn 12 that is different from the first shrinkage yarn 11. In the warp yarns 10 of this example, the first shrinkage yarn 11 and the second shrinkage yarn 12 are mixed. That is, the first shrinkage yarn 11 and the second shrinkage yarn 12 are mixed to form one warp yarn 10. The first shrinkage yarn 11 and the second shrinkage yarn 12 may have different heat shrinkage properties. In this example, a case where the warp yarns 10 include a shrinkage yarn will be described, but they may not include a shrinkage yarn.

[0025] By including shrinkage yarns in the warp yarns 10, the crimps can be spread laterally, making the stitches disappear. In this example, by using different shrinkage yarns, such as the first shrinkage yarn 11 and the second shrinkage yarn 12, for the warp yarns 10, the stitches can be made even less visible. Three or more shrinkage yarns may be used for the warp yarns 10. By including shrinkage yarns in the fabric 100, the yarns can be made bulging, increasing its thickness. By including shrinkage yarns, the voids in the fabric 100 can be increased, making it easier to press the fabric 100 with a mold and creating the unevenness of the embossing process.

[0026] The surface gloss of the fabric 100 can be adjusted as desired by adjusting the crimp of the first shrinkage yarn 11 and the second shrinkage yarn 12. In this way, warp yarns 10 containing any shrinkage yarn may be selected from the viewpoints of the surface gloss and embossing of the fabric 100. Similarly, a plurality of different shrinkage yarns may be used for the weft yarn.

[0027] Fig. 4 shows an example of textured yarn used for the warp yarn 510 according to the comparative example. Unlike the warp yarn 10 of the example, the warp yarn 510 does not contain multiple shrink yarns. The false twist shape of the warp yarn 510 is visible, making it easy to distinguish the stitches. Therefore, when fabric is formed using the warp yarn 510, stitches may remain in the fabric.

[0028] 5 shows an example of a method for manufacturing the fabric 100. In this example, the fabric 100 is produced using an embossing machine 200. The embossing machine 200 includes a mold 210 and a low-density member 220. The low-density member 220 includes a material that is lower in density than the fabric 100. The low-density member 220 may be a material such as polyurethane. A material that is higher in density than the low-density member 220 may be placed below the low-density member 220.

[0029] In step S100, a leather-like fabric 100 is prepared. A low-density member 220 is placed below the prepared fabric 100. A mold 210 may be placed above the low-density member 220. The mold 210 may be a roll-shaped or plate-shaped mold having concaves and convexes corresponding to the embossing pattern to be applied to the fabric 100. The mold 210 may be heated to emboss the fabric 100. The heating temperature for embossing using the mold 210 may be below the glass transition point of the fabric 100. The heating temperature of the mold 210 is not limited thereto. The mold 210 may have various shapes or depths depending on the dimensions of the embossed convex and concave portions. When a roll-shaped mold 210 is used, the embossing depth De may be controlled by adjusting conditions such as the temperature, pressure, and conveyor speed of the mold 210. When a plate-shaped mold 210 is used, the embossing depth De may be controlled by adjusting conditions such as the temperature, pressure, and holding time of the mold 210 during processing.

[0030] In step S102, the fabric 100 is embossed using the mold 210. In this example, the fabric 100 is embossed with the low-density member 220 placed below the fabric 100. As a result, the embossing depth of the fabric 100 may be 50 μm or more and 400 μm or less. The embossing machine 200 uses the mold 210 to heat the surface of the fabric 100. Here, surface heating refers to heating a wider surface area, rather than applying high frequency waves to the fabric to process a portion of the fabric, as in a high-frequency welder.

[0031] In step S104, the embossed fabric 100 is removed from the embossing machine 200. The fabric 100 of this example has a high-quality leather-like texture with improved relief expression due to the type of material and the embossing method used.

[0032] The fabric 100 may be dipped in a functional agent such as a water repellent agent to impart functionality such as water repellency to the leather-like fabric 100. The functional agent may have any function such as flame retardancy. The fabric 100 may be dipped in a plurality of functional agents at once.

[0033] Although the present invention has been described above using embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the claims that such modifications and improvements can also be included within the technical scope of the present invention.

[0034] It should be noted that the execution order of each process, such as operations, procedures, steps, and stages, in the devices, systems, programs, and methods shown in the claims, specifications, and drawings is not specifically stated as "before," "prior to," etc., and that the processes can be performed in any order unless the output of a previous process is used in a subsequent process. Even if the operational flow in the claims, specifications, and drawings is described using "first," "next," etc. for convenience, this does not mean that the processes must be performed in this order. [Explanation of symbols]

[0035] 10....warp thread, 11...first shrinkable thread, 12...second shrinkable thread, 100...fabric, 200...embossing machine, 210...mold, 220...low-density member, 510...warp thread

Claims

1. A leather-like fabric using at least one of embossed polyester, nylon, acrylic, linen, cotton, silk, rayon, and wool, The embossing depth of the fabric is 50 μm or more and 400 μm or less. Leather-like fabric.

2. The fabric satisfies at least one of the evaluation standards of JIS L1096, L1093, L1092, L1076, L0860, L0849, L0844, or L0842. The leather-like fabric according to claim 1.

3. A predetermined first shrinkage thread and a second shrinkage thread different from the first shrinkage thread, The first shrinkable yarn and the second shrinkable yarn are mixed. The leather-like fabric according to claim 1 or 2.

4. The single yarn has a decitex of 0.05 or more and 0.7 or less. The leather-like fabric according to claim 1 or 2.

5. The warp thread density is 200 or more and 300 or less. The leather-like fabric according to claim 1 or 2.

6. The thickness of the fabric is 0.3 mm or more and 1.5 mm or less. The leather-like fabric according to claim 1 or 2.

7. The stage of preparing the leather-like fabric, embossing the fabric; Equipped with The embossing depth of the fabric is 50 μm or more and 400 μm or less. How to make leather-like fabric.

8. The step of embossing the fabric comprises: placing a low-density member under the fabric that is lower in density than the fabric; embossing the fabric with the low-density member positioned underneath the fabric; Contains A method for producing the leather-like fabric according to claim 7.

9. The embossing step includes a step of heating the surface of the fabric using an embossing machine that uses a roll-shaped or plate-shaped mold. A method for producing the leather-like fabric according to claim 7 or 8.

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