Method for manufacturing clothing fabrics, and clothing fabrics

Abstract

To provide a method for manufacturing clothing fabrics that regulate heat retention, and to provide clothing fabrics. [Solution] The method for manufacturing clothing fabric is characterized by comprising: a defibration step S2 in which raw material C is dry-processed to produce fibers; a mixing step S3 in which additives are mixed with the fibers obtained in the defibration step S2 to produce a mixture; a deposition step S4 in which the mixture is deposited in air on a breathable fabric N1 that will become the first layer L1 to produce a web W that will become the second layer L2; a molding step S5 in which the fabric N1 and the web W are stacked and molded by heating and pressurizing; a bonding step S6 in which a fabric N3 that will become the third layer L3 is attached to at least one of the first layer L1 and the second layer L2; and a coating step S7 in which a treatment agent that improves heat retention is coated onto the third layer L3.

Description

Technical Field

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

Background Art

[0002] In recent years, in order to solve problems such as resource depletion and increasing waste, mechanisms and technologies for recycling used clothing have been studied. For example, Patent Document 1 discloses a technique for manufacturing a fiber sheet by defibrating fabric in a dry manner.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, the technique described in Patent Document 1 has a problem that it is difficult to change the heat retention of the fabric to be manufactured when applied to the manufacture of fabric for clothing. The heat retention required for clothing varies depending on the use and the like. In the above technique, the adjustment of heat retention is not mentioned in the fiber sheet to be manufactured. That is, a method for manufacturing fabric for clothing that can adjust heat retention has been demanded.

Means for Solving the Problems

[0005] A method for manufacturing garment fabric is characterized by comprising: a defibration step of dry-processing a cloth to produce fibers; a mixing step of mixing an additive with the fibers obtained in the defibration step to produce a mixture; a deposition step of depositing the mixture in air onto a breathable first layer fabric to produce a second layer web; a molding step of stacking the first layer fabric and the web and molding them by heating and pressurizing; a bonding step of attaching a third layer fabric to at least one of the first and second layers; and a coating step of coating the third layer with a treatment agent to improve heat retention.

[0006] The garment fabric is characterized by comprising: a first layer having breathability; a second layer consisting of a web formed by depositing a mixture of fibers obtained by dry defibration of the fabric and additives in the air; and a third layer attached to at least one of the first and second layers, coated with a treatment agent that improves moisture retention. [Brief explanation of the drawing]

[0007] [Figure 1] A schematic cross-sectional view showing the structure of a garment fabric according to the embodiment. [Figure 2] A schematic cross-sectional view showing other forms of clothing fabric. [Figure 3] A schematic cross-sectional view showing other forms of clothing fabric. [Figure 4] A flowchart illustrating the manufacturing process for clothing fabrics. [Figure 5] A schematic diagram showing the configuration of a fabric manufacturing apparatus used in the production of clothing fabrics. [Modes for carrying out the invention]

[0008] The embodiments described below illustrate a garment fabric having a multilayer structure and a method for manufacturing the same, with reference to the drawings. In the following figures, X, Y, and Z axes are added as mutually orthogonal coordinate axes as needed, 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. For illustrative purposes, the size of each component is different from that of actual components.

[0009] 1. Fabric for clothing As shown in Figure 1, the garment fabric F1 according to this embodiment has a multilayer structure including a first layer L1, a second layer L2, and a third layer L3. Garment fabric F1 is an example of the garment fabric of the present invention and is manufactured by the garment fabric manufacturing method described later. Garment fabric F1 is suitable for, for example, coats because it has improved heat retention.

[0010] The first layer L1 comprises a base layer L1b and an adhesive layer L1a. The third layer L3 comprises a base layer L3b and an adhesive layer L3a. In the garment fabric F1, the base layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, the second layer L2, the adhesive layer L3a of the third layer L3, and the base layer L3b of the third layer L are laminated in this order from bottom to top. When processing the garment fabric F1 into garments, it is preferable to use the third layer L3 on the outside of the garment from the viewpoint of the garment's heat retention and breathability.

[0011] The thickness of the garment fabric F1 is set appropriately according to the intended use and form of the garment to which it is applied. The thickness of the garment fabric F1 is not particularly limited, but for example, it is set to 0.30 mm or more and 2.00 mm or less. This improves the flexibility and strength of the garment fabric F1. Furthermore, since the first layer L1 and the third layer L3 are laminated on the second layer L2, the strength of the garment fabric F1 is ensured while making the thickness of the second layer L2 relatively thin. In this specification, thickness refers to the dimension in the direction in which the first layer L1, the second layer L2, and the third layer L3 are laminated, i.e., the direction along the Z axis.

[0012] The first layer L1 is breathable. When the third layer L3 is used on the outside of the garment, that is, when the first layer L1 is used on the inside of the garment facing the body, stuffiness during wear is reduced and comfort is improved. Furthermore, in the manufacture of the garment fabric F1, the breathability of the first layer L1 can be used to promote the deposition of fibers and other materials that will become the second layer L2 on the first layer L1. Specifically, by drawing in air in which the fibers and other materials are dispersed through the first layer L1, the formation of a fiber-containing web is promoted. The manufacturing method and process for the garment fabric F1 will be described in the following section on garment fabric manufacturing methods.

[0013] In this specification, permeability is defined as the amount of air passing through a test specimen according to the JIS permeability test (L1096 2010 8.26.1 Method A). In this specification, permeability is defined as the amount of air obtained by the above test method being 10 cm³. 3 / cm 2 This refers to something lasting more than a second.

[0014] The thickness of the first layer L1 is not particularly limited, but is preferably, for example, 0.01 mm or more and 0.20 mm or less. This improves the flexibility and strength of the garment fabric F1.

[0015] The base layer L1b is breathable. The base layer L1b forms one surface of the garment fabric F1. The base layer L1b is a sheet such as a woven, knitted, or nonwoven fabric containing polyester. As such, polyester has relatively good strength, which can improve the thinness and strength of the garment fabric F1.

[0016] The base layer L1b is not limited to being made of polyester, but may be a sheet containing polyester and other resins, or a sheet made of a resin other than polyester.

[0017] The adhesive layer L1a is interposed between the substrate layer L1b and the second layer L2. The adhesive layer L1a adheres the first layer L1 and the second layer L2 together, ensuring adhesive strength between the first layer L1 and the second layer L2.

[0018] The subsequent layer L1a contains an adhesive. Examples of the adhesive material include known adhesives such as polyester resin, acrylic resin, silicone resin, and urethane resin, and known adhesives such as epoxy-based, acrylic-based, cyanoacrylate-based, urethane-based, and vinyl acetate-based adhesives. The adhesive of the adhesive layer L1a may be cured by heat applied in the molding process among the manufacturing processes of the clothing fabric F1 described later.

[0019] The adhesive layer L1a also has air permeability. Specifically, the adhesive layer L1a is formed so as not to inhibit the air permeability of the first layer L1. Examples of such a form of the adhesive layer L1a include those in which the above-mentioned adhesive materials and adhesives are coated in a planar mesh shape, and those having a plurality of holes penetrating in the direction along the Z-axis.

[0020] Note that the adhesive layer L1a is not an essential component, and the first layer L1 may be composed only of the base material layer L1b. In this case, the first layer L1 and the second layer L2 are bonded together by the binding action of the additives contained in the second layer L2.

[0021] The first layer L1 may be colored. When the base material layer L1b and the adhesive layer L1a are formed of the above-mentioned materials, they generally have a white color tone. If the second layer L2 is colored, the color tones of the first layer L1 and the second layer L2 will be relatively different. In this case, when the clothing fabric F1 is processed into clothing, the difference in color tone between the first layer L1 and the second layer L2 is likely to be noticeable. On the other hand, if the first layer L1 is colored to a color tone close to that of the second layer L2, the difference in color tone can be made less noticeable when processed into clothing.

[0022] Also, when the first layer L1 is used on the outside of the clothing, the designability of the clothing is improved by coloring the first layer L1.

[0023] For coloring the first layer L1, known methods such as digital printing (including inkjet printing) or analog printing can be applied. The coloring of the first layer L1 may be carried out in advance during the manufacturing stage of the fabric that will become the first layer L1, or it may be carried out during the manufacturing process of the garment fabric F1.

[0024] The second layer L2 is a nonwoven fabric containing multiple fibers obtained by defibrating a cloth or the like, and additives such as binders. The second layer L2 consists of a web formed by the accumulation of multiple fibers in the air. In the following description, the multiple defibrated fibers may also be simply referred to as fibers. As will be described in detail later, the defibration process to obtain the fibers is carried out in a dry manner. In this specification, "dry" refers to a process carried out in the air, such as the atmosphere, rather than in a liquid such as water.

[0025] Fibers are one of the main components of the second layer L2 and, together with the binder, affect the physical properties of the second layer L2, such as its mechanical strength. From the perspective of resource recycling, it is preferable to use fibers obtained by defibrating fabrics derived from used clothing. Examples of fabric types include knitted fabrics, plain weave fabrics, and pile fabrics. Nonwoven fabrics may also be included in the fabric.

[0026] When recycled clothing is used as the fiber material, various types of fibers may be mixed in the second layer L2. Depending on the material and form of the fibers, the heat retention properties of the formed second layer L2 may change. In other words, conventionally, it has been difficult to adjust the heat retention properties of the second layer L2. Also, as mentioned above, since the first layer L1 is breathable, it has also been difficult to adjust the heat retention properties of the first layer L1. In contrast, the garment fabric F1 allows for adjustment of heat retention properties through the third layer L3, which is coated with a treatment agent.

[0027] Furthermore, the heat retention of the garment fabric F1 can be adjusted not only by the third layer L3, but also by changing the thickness and density of the second layer L2. Changing the thickness and density of the second layer L2 alters the volume of voids contained within the second layer L2, making it easier to adjust the heat retention.

[0028] Examples of fibers include natural fiber materials such as cotton, hemp, wool, silk, and regenerated cellulose, as well as synthetic fibers such as polypropylene, polyester, and polyurethane.

[0029] The fibers may be one type of this material alone or a combination of two or more. In particular, among the above fiber materials, it is preferable that the fabric contains cotton or wool, considering the ease of obtaining used clothing and the physical properties of the fibers.

[0030] The weighted average fiber length of the defibrated fibers is preferably between 0.5 mm and 2.0 mm. This prevents the fibers from becoming excessively short, allowing them to intertwine appropriately 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.

[0031] Considering the reuse of garments processed from garment fabric F1, the fibers of the second layer L2 are preferably white. However, the fibers are not limited to white fibers and may include fibers that have been pre-dyed with dyes. On the other hand, it is preferable that the second layer L2 does not contain colorants such as pigments. Not containing colorants means not containing colorants that have been intentionally added. The second layer L2 may contain colorants such as pigment particles that have been unintentionally mixed in.

[0032] The basis weight of the second layer L2 is 100g / m². 2 More than 180g / m 2 The following is preferable. Basis weight is the number of grams per square meter of the surface area of ​​a single garment fabric F1 that aligns with the XY plane. When the basis weight of the second layer L2 is within the above range, a good balance between thinness and strength is achieved in the second layer L2. The basis weight of the second layer L2 is adjusted by the amount of web deposited, i.e., the thickness of the web, during the deposition process when manufacturing the garment fabric F1.

[0033] The thickness of the second layer L2 is not particularly limited, but is preferably, for example, 0.20 mm or more and 0.80 mm or less. This improves the flexibility and strength of the garment fabric F1. The thickness of the second layer L2 is adjusted not only by the thickness of the web as described above, but also by the pressure conditions of the web during the molding process when manufacturing the garment fabric F1.

[0034] The binder is used to bond the fibers together in the second layer L2. The binder is a thermoplastic or thermosetting resin. Examples of resins include thermoplastic synthetic resins such as polyester, as well as natural resins such as shellac, pine resin, dammar, polylactic acid, plant-derived polybutylene succinate, plant-derived polyethylene, and Kaneka's PHBH® (Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)). One of these types of binders may be used alone, or two or more types may be used in combination.

[0035] Other additives besides binders include, for example, flame retardants, antioxidants, UV absorbers, flocculation inhibitors, antibacterial agents, antifungal agents, waxes, and mold release agents.

[0036] The second layer L2 may have a pre-treatment, such as surface treatment, applied to the first surface SF1 that is in contact with the first layer L1, or the second surface SF2 that is in contact with the third layer L3. Surface treatment improves various physical properties such as abrasion resistance. Surface treatment is carried out in the manufacturing process of the garment fabric F1.

[0037] Surface treatments are not particularly limited, but include softening treatments, water-repellent treatments, wrinkle-preventing treatments, and abrasion-resistant treatments. Known fiber treatment agents can be applied to these surface treatments.

[0038] The third layer L3 is attached to the second layer L2 side, which is one of the first layer L1 and the second layer L2. The third layer L3 is coated with a treatment agent that improves the heat retention of the garment fabric F1. As a result, the third layer L3 is responsible for heat retention in the garment fabric F1. When the third layer L3 is used on the outside of the garment, the heat retention when worn is improved. Note that the third layer L3 is not limited to being attached to the second layer L2 side, but may be attached to at least one of the first layer L1 and the second layer L2.

[0039] Here, "thermal retention" as used herein is a general term encompassing properties such as thermal insulation, airtightness, and heat storage. Specifically, thermal retention refers to the property of preventing the body temperature from dropping in response to a decrease in the outside temperature, or preventing body heat from escaping to the outside, when wearing clothing processed from the fabric of the present invention.

[0040] The thickness of the third layer L3 is not particularly limited, but is preferably, for example, 0.01 mm or more and 1.00 mm or less. This improves the flexibility and strength of the garment fabric F1.

[0041] The base layer L3b forms the other surface of the garment fabric F1. The base layer L3b is a sheet such as a woven, knitted, or nonwoven fabric containing polyester. Because polyester has relatively good strength, this can improve the thinness and strength of the garment fabric F1.

[0042] The base layer L3b is not limited to being made of polyester, but may be a sheet containing polyester and other resins, or a sheet made of a resin other than polyester.

[0043] The adhesive layer L3a is interposed between the substrate layer L3b and the second layer L2. The adhesive layer L3a adheres the third layer L3 and the second layer L2 together, ensuring adhesive strength between the third layer L3 and the second layer L2. The adhesive layer L3a contains an adhesive. The adhesive material can be the same as that used for the adhesive layer L1a of the first layer L1.

[0044] Note that the adhesive layer L3a is not an essential component, and the third layer L3 may consist only of the base layer L3b. In this case, the third layer L3 and the second layer L2 are bonded together by the binding action of the additives contained in the second layer L2.

[0045] The treatment agent that improves heat retention is coated onto the base layer L3b. The treatment agent is not particularly limited as long as it improves heat retention, and known chemicals can be used. Specifically, examples of treatment agents include those that form a resin film on the surface to improve airtightness, and those that utilize latent heat to mitigate the temperature drop on the human body side relative to the outside environment.

[0046] The treatment agent is coated onto the third layer L3 during the manufacturing process of the garment fabric F1. As will be described in detail later, the treatment agent coating is applied to the surface of the base layer L3b opposite to the adhesive layer L3a. Therefore, when processing the garment fabric F1 into garments, it is preferable to position the base layer L3b so that the aforementioned surface faces the outside.

[0047] The third layer L3 may be colored in a manner similar to that of the first layer L1. The coloring of the third layer L3 may be carried out at the stage when the fabric that will become the third layer L3 is being prepared, or it may be carried out in the manufacturing process of the garment fabric F1. In this embodiment, the third layer L3 is coated with a treatment agent, and then coloring is applied from the surface of the base layer L3b. As a result, the coloring is applied to the surface of the coating layer formed by the treatment agent, which improves the color development.

[0048] When the third layer L3 is used on the outside of the garment, the design of the garment is improved by coloring. Coloring here includes not only single-color coloring but also the creation of images such as text, patterns, pictures, and photographs by printing. The method described above for the first layer L1 can be applied to color the third layer L3.

[0049] The garment fabric of the present invention may have a different form from garment fabric F1. Garment fabrics F2 and F3, illustrated below, are examples of garment fabrics of the present invention. Garment fabrics F2 and F3 differ from garment fabric F1 in the arrangement of the third layer L3. In the description of garment fabrics F2 and F3, the same reference numerals are used for components identical to those in garment fabric F1, and redundant explanations are omitted.

[0050] As shown in Figure 2, the garment fabric F2 has a multilayer structure including a first layer L1, a second layer L2, and a third layer L3. In garment fabric F2, the layers are stacked in the following order from bottom to top: the base layer L3b of the third layer L, the adhesive layer L3a of the third layer L3, the base layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, and the second layer L2. In other words, in garment fabric F2, the third layer L3 is attached to the first layer L1 side, which is one of the first layer L1 and the second layer L2. This is different from garment fabric F1.

[0051] The third layer L3 is coated with a treatment agent that improves the heat retention of the garment fabric F2. The third layer L3 may also be colored in the same way as the garment fabric F1. When processing the garment fabric F2 into clothing, it is preferable to use the third layer L3 on the outside of the garment from the viewpoint of garment heat retention and other factors.

[0052] As shown in Figure 3, the garment fabric F3 has a multilayer structure including a first layer L1, a second layer L2, and two third layers L3. In garment fabric F3, the layers are stacked in the following order from bottom to top: the base layer L3b of the third layer L, the adhesive layer L3a of the third layer L3, the base layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, the second layer L2, the adhesive layer L3a of the third layer L3, and the base layer L3b of the third layer L3. In other words, in garment fabric F2, the third layer L3 is attached to both the first layer L1 and the second layer L2, that is, to the first layer L1 side and the second layer L2 side. This is different from garment fabric F1.

[0053] Each of the two third layers L3 is coated with a treatment agent that improves the heat retention of the garment fabric F2. As a result, garment fabric F3 has improved heat retention compared to garment fabrics F1 and F2. The heat retention can be adjusted by changing the arrangement and number of third layers L3 relative to the first layer L1 and the second layer L2.

[0054] Both or one of the two third layers L3 may be colored in the same way as the garment fabric F1.

[0055] 2. Method for manufacturing garment fabrics The method for manufacturing garment fabric F1 according to this embodiment is an example of the garment fabric manufacturing method of the present invention. The method for manufacturing garment fabric F1 is an example and is not limited to the following configuration and sequence. The method for manufacturing garment fabric F1 can also be applied to the manufacture of garment fabrics F2 and F3.

[0056] As shown in Figure 4, the method for manufacturing garment fabric F1 comprises a raw material supply step S1, a defibration step S2, a mixing step S3, a deposition step S4, a molding step S5, a bonding step S6, and a coating step S7. In the method for manufacturing garment fabric F1, the garment fabric F1 is manufactured by going through each step in the order described above, from the upstream raw material supply step S1 to the downstream coating step S7.

[0057] A specific example of a method for manufacturing garment fabric F1 will be described along with a fabric manufacturing apparatus 1 for manufacturing garment fabric F1. The fabric manufacturing apparatus 1 in this embodiment is an example and is not limited to the following configuration. In the fabric manufacturing apparatus 1, the end of the conveying direction for raw materials, fabric, web, and work-in-progress may be referred to as downstream, and the side going upstream in the conveying direction may be referred to as upstream.

[0058] As shown in Figure 5, the dough manufacturing apparatus 1 is equipped with a supply unit 5, a crushing unit 10, a defibration unit 30, a mixing unit 60, a stacking unit 100, a web transport unit 70, a molding unit 150, a bonding unit 73, and a processing unit 170, among others, arranged from upstream to downstream. The dough manufacturing apparatus 1 is also equipped with a control unit 28 that comprehensively controls the operation of each of the above components.

[0059] The raw material supply process S1 is carried out in the supply unit 5. The supply unit 5 supplies raw material C to the crushing unit 10. The supply unit 5 is equipped with, for example, an automatic feeding mechanism (not shown) to continuously and automatically feed raw material C into the crushing unit 10. Raw material C is fabric such as used clothing.

[0060] The coarse crushing unit 10 shreds the raw material C supplied from the supply unit 5 into fine pieces in an atmosphere such as air. The coarse crushing unit 10 is a shredder or cutter mill having coarse crushing blades 11. The raw material C is shredded by the coarse crushing blades 11 to become fine pieces of raw material C. The planar shape of the fine pieces is, for example, a few millimeters square or irregular. The fine pieces are collected in the quantitative supply unit 50. The raw material C may be pre-shredded before being fed into the supply unit 5.

[0061] The quantitative feeding unit 50 weighs out pieces of raw material C and supplies them to the hopper 12 in a fixed quantity. The quantitative feeding unit 50 is, for example, a vibrating feeder. The pieces of raw material C supplied to the hopper 12 are transported through the pipe 20 to the inlet 31 of the defibration unit 30. Then the process proceeds to the defibration process S2.

[0062] The defibration process S2 is performed in the defibration unit 30. The defibration unit 30 defibrates the fine fragments derived from the raw material C, which is a fabric, in a dry manner to generate and extract the fibers contained in the raw material C. The defibration unit 30 is equipped with an inlet 31, an outlet 32, a stator 33, a rotor 34, and an airflow generation mechanism (not shown). The fine fragments of the raw material C are introduced into the interior of the defibration unit 30 through the inlet 31 by the airflow from the airflow generation mechanism.

[0063] The stator 33 and rotor 34 are positioned inside the defibration section 30. The stator 33 has a substantially cylindrical inner surface. The rotor 34 rotates along the inner surface of the stator 33. The fine pieces of raw material C are sandwiched between the stator 33 and the rotor 34 and defibrated by the shear force generated between them.

[0064] The fibers generated in the defibration section 30 are discharged into the pipe 40 from the outlet 32. The pipe 40 communicates with the inside of the defibration section 30 and the inside of the accumulation section 100. The fibers are transported from the defibration section 30 to the accumulation section 100 by the airflow generated by the airflow generation mechanism. A mixing section 60 is provided in the pipe 40 between the defibration section 30 and the accumulation section 100.

[0065] Although not shown in the diagram, the fabric manufacturing apparatus 1 may include a separation mechanism between the defibration section 30 and the mixing section 60 to remove impurities and other contaminants contained in the defibrated fibers. Examples of separation mechanisms include known devices such as sieves. According to the separation mechanism, the amount of impurities is reduced, and high-purity fibers can be used as the material for the second layer L2. Then the process proceeds to the mixing process S3.

[0066] The mixing process S3 is carried out in the mixing unit 60. The mixing unit 60 mixes the fibers obtained in the defibration process S2 with additives such as binders to produce a mixture. The mixing unit 60 includes hoppers 13 and 14, supply pipes 61 and 62, and valves 65 and 66. In the mixing unit 60, the fibers and binders are mixed in air to form a mixture. As mentioned above, it is preferable that the mixture does not contain colorants. Here, "not containing colorants" means that colorants such as pigments are not intentionally added to the mixture. In other words, the mixture may contain colorants such as dyes that have permeated the fibers, or colorants that have been unintentionally mixed in.

[0067] Hopper 13 communicates with the inside of pipe 40 via supply pipe 61. In supply pipe 61, valve 65 is provided between hopper 13 and pipe 40. Hopper 13 supplies binder into pipe 40. Valve 65 adjusts the mass of binder supplied from hopper 13 to pipe 40. This adjusts the mixing ratio of fibers to binder. The binder may be supplied in the form of a powder or particles, or it may be supplied in a molten state.

[0068] Hopper 14 is connected to the inside of pipe 40 via supply pipe 62. Valve 66 is provided between hopper 14 and pipe 40 in supply pipe 62. Hopper 14 supplies additives other than binders into pipe 40. Valve 66 adjusts the mass of additives other than binders supplied from hopper 14 to pipe 40. This adjusts the mixing ratio of the additives to the fibers and binders. Alternatively, the additives other than binders may be mixed with the binder beforehand and supplied from hopper 13. Furthermore, if no additives other than binders are added to the mixture, hopper 14, supply pipe 62, and valve 66 may be omitted.

[0069] The fibers and binders are transported through the pipe 40 to the deposition section 100 and mixed together to form a mixture. To promote the formation of the mixture in the pipe 40 and to improve the transportability of the mixture, a blower or the like may be placed in the pipe 40 to generate airflow. The mixture is introduced from the pipe 40 to the deposition section 100 via the connection section 42. Then the process proceeds to deposition step S4.

[0070] The deposition process S4 is carried out in the deposition section 100. In the deposition section 100, the mixture is deposited in air onto the breathable fabric N1 to generate a web W which will become the second layer L2. Fabric N1 becomes the first layer L1 of the garment fabric F1. In other words, the web W is formed by depositing a mixture containing defibrated fibers and additives in air onto the fabric N1 which will become the first layer L1. This makes it easy to form the web W and change its basis weight.

[0071] The deposition unit 100 includes a drum unit 101, a housing unit 102 that accommodates the drum unit 101, and a dough supply unit 71 that supplies the dough N1. The deposition unit 100 takes the mixture from the pipe 40 into the drum unit 101. Then, it deposits the mixture dry onto the dough N1 supplied from the dough supply unit 71.

[0072] Below the stacking section 100, a web transport section 70 is arranged, which includes a mesh belt 122 and a suction mechanism 110. The suction mechanism 110 is positioned opposite the drum section 101, with the mesh belt 122 in between, in the direction along the Z-axis.

[0073] The drum section 101 includes a blade member 101a that is rotationally driven by a motor (not shown), and a substantially cylindrical sieve section 101b that is positioned mainly below the blade member 101a. The blade member 101a loosens tangled fibers as it rotates. The sieve section 101b allows particles such as fibers and mixtures smaller than the mesh opening of the sieve to pass from the inside to the outside. As a result, the mixture, with its tangled fibers loosened in the drum section 101, is dispersed into the air inside the housing section 102.

[0074] 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 ensures that the adhesive layer L1a and the web W are in contact. If release paper is attached to the adhesive layer L1a of the fabric N1, the fabric supply unit 71 may be equipped with a mechanism to separate the release paper from the fabric N1. It should be noted that pre-colored fabric N1 may also be used.

[0075] The fiber-containing mixture is dispersed from the inside of the sieve section 101b into the air inside the housing section 102. Then, the fiber-containing mixture randomly accumulates above the fabric N1 as it is conveyed on the mesh belt 122. As a result, the fibers in the web W are less likely to be oriented in a particular direction.

[0076] The sieve section 101b does not need to have the function of separating large fibers from the mixture. That is, the drum section 101 may loosen the fibers of the mixture and release all of the mixture into the housing section 102. The mixture dispersed in the air inside the housing section 102 is deposited on the upper surface of the fabric N1 by gravity and the suction force of the suction mechanism 110.

[0077] The basis weight of the garment fabric F1 is adjusted by the basis weight of fabric N1, fabric N3 (described later), and web W. The basis weight of web W is adjusted by the rotation speed of the blade member 101a, the amount of mixture supplied to the deposition section 100 per hour, and the conveying speed of fabric N1 by the mesh belt 122.

[0078] Here, in the deposition process S4, the thickness of the second layer L2 of the garment fabric F1 may be adjusted by changing the thickness of the web W. This changes the amount of air contained in the second layer L2, and thus changes the heat retention of the second layer L2. Therefore, in addition to the third layer L3, the heat retention can also be adjusted in the second layer L2, making it even easier to adjust the heat retention of the garment fabric F1. The thickness of the web W can be adjusted by the basis weight of the web W or the pressure applied during the molding process S5.

[0079] The mixing ratio of fibers to additives is not particularly limited and is adjusted as appropriate depending on the type of additive. For example, in the web W, the mass ratio of fibers to binder is preferably in the range of 9:1 to 5:5 in terms of fibers to binder. This allows for a balance of various physical properties of the garment fabric F1.

[0080] The web conveying section 70 includes a mesh belt 122 and a suction mechanism 110. The web conveying section 70 promotes the deposition of the mixture onto the fabric N1 by the suction mechanism 110. The web conveying section 70 also conveys the web W formed from the mixture downstream by the rotation of the mesh belt 122.

[0081] The suction mechanism 110 is positioned below the drum section 101. The suction mechanism 110 draws air from inside the housing section 102 through the multiple holes in the mesh belt 122 and the breathable fabric N1. As a result, the mixture released to the outside of the drum section 101 is drawn downward along with the air and deposited on the upper surface of the fabric N1. A known suction device, such as a blower, is employed in the suction mechanism 110.

[0082] The multiple holes in the mesh belt 122 allow air to pass through but make it difficult for fibers and binders contained in the mixture to pass through. The mesh belt 122 is an endless belt and is stretched by four tension rollers 121.

[0083] The mesh belt 122 moves downstream as the tension roller 121 rotates. In other words, the mesh belt 122 rotates clockwise in Figure 4. As the mesh belt 122 is rotated by the tension roller 121, the mixture is continuously deposited on the fabric N1, forming a web W. The web W contains a relatively large amount of air and is soft and puffy. The web W, along with the fabric N1, is conveyed downstream as the mesh belt 122 moves.

[0084] A humidifier 130 may be placed downstream of the deposition section 100 to humidify the web W by spraying water onto it. This suppresses the scattering of fibers, binders, and other materials contained in the web W. Alternatively, a water-soluble additive may be added to the water used for humidification, and the web W, which will become the second layer L2, may be surface-treated in parallel with the humidification.

[0085] The web W and fabric N1 are transported downstream by the mesh belt 122, detached from the mesh belt 122, and drawn into the dancer roller 141. The dancer roller 141 is provided to ensure processing time for the downstream molding process S5. Specifically, since the molding process S5 is a batch process, the dancer roller 141 is moved up and down to ensure processing time for the molding process S5 for the web W and fabric N1 that are continuously supplied from the accumulation section 100. The web W and fabric N1 are sent downstream via the dancer roller 141 and then proceed to the molding process S5.

[0086] The molding process S5 is performed in the molding unit 150. The molding unit 150 layers the dough N1, which will become the first layer L1, and the web W, and molds them by heating and pressing. The molding unit 150 is a heating press device and comprises an upper substrate 152 and a lower substrate 151. The upper substrate 152 and the lower substrate 151 press the web W and dough N1 between them and heat the web W and dough N1 with built-in heaters. In addition, the molding process S5 may be performed continuously using a pair of heating rollers or the like.

[0087] The web W is compressed from above and below by pressure, increasing its density, and the binder melts upon heating, wetting and spreading between the fibers. When heating ends and the binder solidifies in this state, the fibers are bonded together by the binder. In addition, the fabric N1 and the web W adhere to each other, with fabric N1 becoming the first layer L1 and web W becoming the second layer L2.

[0088] The pressurization and heating conditions in the molding section 150 are appropriately adjusted depending on the desired density of the garment fabric F1, the melting point of the binder, or the curing temperature. Although not particularly limited, for example, the pressurization condition is a pressure of 0.01 MPa or higher, and the heating condition is a temperature of 90°C or higher.

[0089] In molding step S5, the thickness of the second layer L2 may be adjusted by changing the pressure applied to the molding section 150. This changes the density of voids in the second layer L2, allowing for adjustment of the heat retention properties of the second layer L2.

[0090] In the molding section 150, the first layer L1 and the second layer L2 are formed by integrating the fabric N1 and the web W. Then the process proceeds to the bonding process S6.

[0091] In the bonding step S6, the fabric N3, which will become the third layer L3, is bonded to at least one of the first layer L1 and the second layer L2. In the garment fabric F1, the third layer L3 is bonded to the second layer L2. Therefore, in the bonding step S6, the fabric N3, which will become the third layer L3, is bonded to the upper surface of the second layer L2. Fabric N3 includes an adhesive layer L3a and a base layer L3b, which are not shown. Fabric N3 may be pre-colored, similar to fabric N1.

[0092] The bonding process S6 is performed in the fabric supply unit 72 and the bonding unit 73. The fabric supply unit 72 continuously feeds the roll-shaped fabric N3 above the second layer L2. At this time, the adhesive layer L3a of the fabric N3 is positioned facing downwards, and the adhesive layer L3a is brought into contact with the second layer L2. If release paper is attached to the adhesive layer L3a of the fabric N3, the fabric supply unit 72 may be equipped with a separation mechanism to separate the release paper from the fabric N3.

[0093] The adhesive section 73 adheres the upper surface of the second layer L2 to the adhesive layer L3a of the fabric N3. The adhesive section 73 is a pair of pressure rollers that press the first layer L1 and the second layer L2 and the fabric N3 together from above and below. This forms the third layer L3 of the garment fabric F1. Alternatively, the adhesive section 73 may be equipped with a heating mechanism to bond the fabric N3 and the second layer L2 by heat and pressure.

[0094] Here, when manufacturing the garment fabric F2 described above, fabric N3 is attached from below the first layer L1. When manufacturing the garment fabric F3 described above, fabric N3 is attached both below the first layer L1 and above the second layer L2. Then the process proceeds to the coating process S7.

[0095] The coating process S7 is performed in the processing unit 170. The processing unit 170 coats the third layer L3 with a treatment agent that improves heat retention. The processing unit 170 is, for example, a spraying device that sprays a solution of the treatment agent onto the third layer L3. The processing unit 170 is not limited to a spraying method, but may also use known methods such as dropping, inkjet, and roller coating.

[0096] The treatment agent solution applied to the third layer L3 partially penetrates into the substrate layer L3b, while the rest remains on the surface of the substrate layer L3b. Subsequently, the volatile components of the treatment agent solution volatilize, forming a coating layer of the treatment agent on the surface and inside the substrate layer L3b. The volatilization of the volatile components may be by air drying, or by evaporation using a blower mechanism or heating mechanism (not shown).

[0097] In coating step S7, the treatment agent is coated onto the third layer L3. The treatment agent can be a resin solution or emulsion that forms a resin film, or a slurry or powder containing a latent heat storage material. The coating method is not limited to spraying; it can be changed to roller coating, inkjet coating, etc., depending on the properties of the treatment agent.

[0098] Examples of treatment agents for forming a resin film include emulsions of urethane resin or acrylic resin, thermosetting or electron beam curing monomers, and their curing agents. Commercially available products may be used as the above treatment agents. According to this, the resin film formed from the treatment agent enhances the airtightness of the garment fabric F1, suppressing the intrusion of cold air from the outside and the dissipation of heat from the human body. Therefore, the heat retention of the third layer L3 can be further improved.

[0099] Examples of treatment agents that utilize latent heat include those containing known latent heat storage materials such as fatty acid compounds and paraffins. Commercially available products such as Miki Riken Kogyo's heat storage paraffin PCM series and Sumitomo Chemical's Conforma (registered trademark) may be used as latent heat storage materials. With this, the heat stored in the coating layer is released, suppressing the temperature drop on the human body side. As a result, the heat retention of the third layer L3 can be further improved.

[0100] The surface of the third layer L3, that is, the coating layer of the base material layer L3b, may be colored with pigment ink or the like. By coloring the surface of the coating layer, the color development and other properties of the coloring are improved compared to when the fabric N3 is pre-colored. The coloring of the third layer L3 is not limited to coloring the entire surface of the third layer L3 with a single color, but may also be done to form images such as text, patterns, pictures, or photographs.

[0101] The coloring apparatus for coloring the third layer L3 is not particularly limited, and known apparatuses such as ink ejection devices and ink coating devices can be used. When the garment fabric F1 is to be produced in small quantities with a wide variety of products, it is preferable to use an ink ejection device that includes an inkjet head. In addition, a pretreatment may be applied to the coating layer of the third layer L3 as a preliminary step before coloring. The pretreatment improves, for example, the abrasion resistance and wash fastness of garments processed from the garment fabric F1.

[0102] A cutting section (not shown) may be provided downstream of the processing section 170 to trim the shape of both ends of the garment fabric F1 along the Y-axis. Specifically, the cutting section is equipped with a vertical blade. The vertical blade cuts the strip-shaped garment fabric F1 along the conveying direction. This trims the edges of both ends of the garment fabric F1. The cutting section may be located between the adhesive section 73 and the processing section 170.

[0103] After the garment fabric F1 is coated in the coating process S7, it is wound into a roll by a winding mechanism (not shown). Thus, the garment fabric F1 is manufactured.

[0104] According to this embodiment, the following effects can be obtained.

[0105] The heat retention properties of the garment fabric F1 being manufactured can be adjusted. Specifically, by attaching fabric N3, which will become the third layer L3, to the second layer L2, and coating the third layer L3 with a treatment agent, the heat retention properties are adjusted to be higher compared to when the treatment agent is not applied. Furthermore, in garment fabric F3, by attaching fabric N3, which will become the third layer L3, to both the first layer L1 and the second layer L2, and coating both third layers L3 with a treatment agent, the heat retention properties are further enhanced. As a result, the heat retention properties change depending on whether the third layer L3 is attached to either the first layer L1 or the second layer L2, or to both. Therefore, a method for manufacturing garment fabrics that allows for adjustment of heat retention properties can be provided.

[0106] The heat retention properties of the garment fabrics F1, F2, and F3 can be adjusted. Specifically, by attaching fabric N3, which will become the third layer L3, to the second layer L2 and coating the third layer L3 with a treatment agent, the heat retention is adjusted to be higher compared to when the treatment agent is not applied. Furthermore, in garment fabric F3, by attaching fabric N3, which will become the third layer L3, to both the first layer L1 and the second layer L2, and coating both third layers L3 with a treatment agent, the heat retention is further enhanced. As a result, the heat retention changes depending on whether the third layer L3 is attached to either the first layer L1 or the second layer L2, or to both. Therefore, garment fabrics F1, F2, and F3 with adjustable heat retention properties can be provided. [Explanation of Symbols]

[0107] C... Raw material for fabric, F1, F2, F3... Fabric for clothing, L1... First layer, L2... Second layer, L3... Third layer, N1... Fabric for the first layer, N3... Fabric for the third layer, S2... Fiber defibration process, S3... Mixing process, S4... Lamination process, S5... Molding process, S6... Lamination process, S7... Coating process, W... Web.

Claims

1. The defibration process involves dry defibration of the fabric to produce fibers, A mixing step is performed to produce a mixture by mixing an additive with the fibers obtained in the defibration step, A deposition step in which the mixture is deposited in the air onto a breathable first layer fabric to form a web second layer, A molding process in which the first layer of fabric and the web are stacked and then heated and pressed to form the shape, A bonding step of attaching a third layer fabric to at least one of the first layer and the second layer, A method for manufacturing garment fabric, comprising a coating step of coating the third layer with a treatment agent to improve heat retention.

2. The method for manufacturing clothing fabric according to claim 1, wherein in the coating step, a latent heat storage material is coated as the treatment agent.

3. The method for manufacturing garment fabric according to claim 1, wherein in the coating step, a resin film is formed on the third layer with the treatment agent.

4. The method for manufacturing garment fabric according to claim 1, wherein the thickness of the second layer is adjusted by changing the thickness of the web in the deposition step.

5. The method for manufacturing garment fabric according to claim 1, wherein the thickness of the second layer is adjusted by changing the pressure during the molding process.

6. A breathable first layer, The second layer consists of a web formed by depositing a mixture of fibers obtained by dry defibration of the fabric and additives in the air, A garment fabric characterized by comprising: a third layer attached to at least one of the first layer and the second layer, coated with a treatment agent that improves moisture retention.

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