Pile fabric and method for manufacturing pile fabric
The pile fabric with elastic pile warp threads forming zigzag patterns addresses bulkiness, breathability, and heat retention issues, offering a cost-effective solution with improved manufacturing efficiency.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- YONESAKA PAIRU ORIMONO
- Filing Date
- 2024-12-11
- Publication Date
- 2026-06-23
AI Technical Summary
Existing pile fabrics lack bulkiness, breathability, and heat retention, with high manufacturing costs due to complex structures and flat surfaces, and inner linings that hinder ventilation and air retention.
A pile fabric comprising a surface and backing fabric with non-elastic ground warp and weft threads, and an inner pile section of elastic pile warp threads that form zigzag patterns, creating uneven surfaces and a large internal space for improved bulkiness, breathability, and heat retention, with a simplified manufacturing process.
The fabric achieves enhanced bulkiness, breathability, and heat retention while reducing manufacturing costs through a simplified structure and efficient production, suitable for year-round use.
Smart Images
Figure 2026101778000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a pile fabric and a method for manufacturing the same.
Background Art
[0002] As fabrics for various clothing, bedding, etc., towel fabrics having loop piles and pile fabrics having cut piles are known. These fabrics are suitable for use in winter due to their texture, etc., but are not very suitable for use in summer. However, with the recent global warming and changes in the living environment, there is a growing market demand for fabrics suitable for year-round use.
[0003] As such a fabric, a multi-layer fabric in which a gauze-like plain weave structure is laminated multiple times, as in Patent Document 1, has been proposed. By laminating such a plain weave structure, certain results have been achieved in enhancing the heat retention while maintaining the cool texture of the gauze.
[0004] However, simply laminating the plain weave structure has limitations in enhancing the heat retention, and there are still problems with softness, breathability, etc. Also, in the manufacturing process, since only one weft yarn can be inserted in one shuttle beating, the number of weft yarn insertions increases as the number of layers increases, resulting in a problem of poor production efficiency.
[0005] Therefore, the inventor has developed a pile fabric comprising a front fabric and a back fabric each having a plain weave structure of a gauze weft yarn and a gauze warp yarn, and a three-dimensional middle fabric in which pile warp yarns are bridged in a predetermined arrangement between a pair of opposing base fabrics each having a plain weave structure of a ground weft yarn and a ground warp yarn between the front and back fabrics and intertwined with the ground weft yarn.
[0006] When pile fabrics are constructed in this way, the interior of the fabric has a three-dimensional structure consisting of a pair of base fabrics and pile warp threads that connect these base fabrics in a zigzag pattern. This allows the fabric to be made bulkier compared to simply layering plain weave fabrics. Consequently, it is possible to create a fabric with increased heat retention, flexibility, breathability, and excellent moisture absorption.
[0007] Furthermore, when this pile fabric is manufactured in the following manner, the weft threads, which are arranged in pairs vertically, can be beaten in one at a time during the reeding process, thus improving production efficiency compared to simply layering plain weave structures. Specifically, pairs of sets consisting of one ground weft and two gauze wefts are arranged in a repeating pattern, and the ground warp threads are passed through every other ground weft thread, from the inside to the outside and then back to the inside, to entangle them. The gauze warp threads are also passed between the ground weft and gauze weft threads from the inside to the outside, and between the gauze weft threads themselves, from the outside to the inside, to entangle them. Furthermore, they are also entangled with the ground weft threads at a predetermined pitch, and the pile warp threads are stretched between the upper and lower ground weft threads, passed through the ground weft threads from the inside to the outside and then back to the inside, to entangle them. [Prior art documents] [Patent Documents]
[0008] [Patent Document 1] Japanese Patent Publication No. 2011-032606 [Overview of the project] [Problems that the invention aims to solve]
[0009] However, in the pile fabric described in Patent Document 1, the surface fabric and backing fabric are almost flat, which limits the amount of bulkiness that can be achieved, leaving room for improvement in terms of bulkiness. Furthermore, the complex structure of the fabric, consisting of a middle layer made up of a pair of base fabrics and pile warp threads that connect the base fabrics in a zigzag pattern, resulted in high manufacturing costs. Furthermore, the presence of an inner lining within the fabric could potentially hinder ventilation, leaving room for improvement in terms of breathability. Furthermore, because part of the internal space of the fabric is occupied by the inner lining, there is a risk that the amount of air contained within the internal space will decrease, leaving room for improvement in terms of heat retention.
[0010] Therefore, the problem to be solved by the present invention is to improve the bulkiness, breathability, and heat retention of pile fabrics while keeping manufacturing costs down. [Means for solving the problem]
[0011] To solve the above-mentioned problems, the pile fabric according to the invention comprises a surface fabric woven from ground warp threads and ground weft threads, wherein the ground warp threads are made of non-elastic yarns; a backing fabric woven from ground warp threads and ground weft threads, wherein the ground warp threads are made of non-elastic yarns; and an inner pile section consisting only of pile warp threads that intertwine in a zigzag pattern at regular intervals with the parallel ground weft threads of the surface fabric and the parallel ground weft threads of the backing fabric, wherein the pile warp threads of the inner pile section are made of elastic yarns, and their contraction forms parallel uneven surfaces in the warp direction on the surfaces of the surface fabric and the backing fabric.
[0012] When the pile fabric according to the invention is constructed as described above, the surface of the pile fabric becomes uneven due to the contraction of the elastic yarn, and as a result, the pile fabric as a whole becomes bulkier. Because the inner pile structure of the fabric consists only of pile warp threads that are zigzag-shaped between the outer and inner fabrics, it has excellent breathability and, because a large internal space is formed, it can easily trap air and has excellent heat retention properties.
[0013] Furthermore, compared to the pile fabric described in Patent Document 1, the internal structure is simplified, making it easier to manufacture, reducing the amount of material required, and thus lowering manufacturing costs, including material costs. By appropriately adjusting the pitch of the uneven surface, it becomes easier to set the bulkiness according to the purpose compared to the pile fabric described in Patent Document 1.
[0014] In the pile fabric according to the invention, it is preferable to adopt a configuration in which the pile warp threads of the inner pile portion are heat-shrinkable, and the shrinkage due to heat processing forms parallel uneven surfaces in the warp direction on the surfaces of the outer fabric and the backing fabric. With this configuration, it becomes possible to easily create uneven surfaces on the front and back fabrics simply by heat-treating the woven pile fabric.
[0015] In the pile fabric according to the invention, the pile warp of the inner pile portion consists of a first pile warp and a second pile warp, the first pile warp and the second pile warp are arranged alternately in parallel in the weft direction, the zigzag pattern due to entanglement with the ground weft is symmetrical, and the phases of the uneven portions formed on the surfaces of the outer fabric and the inner fabric are aligned. This configuration allows for the creation of a highly decorative pile fabric with evenly spaced irregularities on both surfaces.
[0016] In the pile fabric according to the invention, a configuration can be adopted in which the unevenness of the surface fabric and the unevenness of the back fabric are uniform. This configuration allows for the creation of a pile fabric with a more aesthetically pleasing design, where the size and pitch of the irregularities on each surface are uniform.
[0017] In the pile fabric according to the invention, the outer fabric and the backing fabric can be made of gauze fabric. This construction results in a pile fabric with a cool, gauze-like texture, making it suitable for year-round use, including during the summer months.
[0018] In order to solve the above problems, regarding the method for manufacturing a pile fabric according to the invention, a step of preparing a face fabric woven from ground warp yarns and ground weft yarns, wherein the ground warp yarns are made of inelastic yarns, and a back fabric woven from ground warp yarns and ground weft yarns, wherein the ground warp yarns are made of inelastic yarns, is provided; a step of interlacing pile warp yarns made of elastic yarns in a zigzag pattern at regular intervals between the facing face fabric and back fabric, between the parallel ground weft yarns of the face fabric and the parallel ground weft yarns of the back fabric; and a step of shrinking the pile warp yarns by heat treatment to form unevenness parallel in the warp direction on the surfaces of the face fabric and the back fabric, are adopted. With such a configuration, since only a heat treatment step is added to the fabric weaving step, the manufacture of the pile fabric according to the invention becomes easy.
[0019] In the method for manufacturing a pile fabric according to the invention, it is preferable to adopt a configuration in which the step of preparing the face fabric and the back fabric is to weave the face fabric and the back fabric in parallel vertically and beat the upper and lower pair of ground weft yarns simultaneously with a reed. With such a configuration, the efficiency of weaving the face fabric and the back fabric, and thus the manufacturing efficiency of the pile fabric according to the invention, is improved.
Effects of the Invention
[0020] Since the pile fabric according to the invention and the method for manufacturing the pile fabric are configured as described above, it is possible to improve the bulkiness, heat retention, and breathability of the entire pile fabric while suppressing the manufacturing cost.
Brief Description of the Drawings
[0021] [Figure 1] Weave diagram of the pile fabric of the embodiment at odd reed counts [Figure 2] Weave diagram of the pile fabric of the embodiment at even reed counts [Figure 3] Schematic cross-sectional view of the pile fabric of the embodiment [Figure 4] Cross-sectional photograph of the pile fabric of the embodiment [Figure 5] Manufacturing schematic diagram of the pile fabric of the embodiment [Modes for carrying out the invention]
[0022] The embodiments of this invention will be described below with reference to the drawings.
[0023] As shown in Figures 1 to 4, the pile fabric 10 according to the embodiment consists of a surface fabric 11 and a backing fabric 12, and an inner pile portion 13 that connects the surface fabric 11 and the backing fabric 12. The outer fabric 11 and the lining fabric 12 are gauze-like fabrics made of a plain weave structure of ground weft and ground warp threads, that is, gauze fabrics made of gauze weft and gauze warp threads. Furthermore, the inner pile section 13 consists only of a first pile warp thread P1 and a second pile warp thread P2 that zigzag between the outer fabric 11 and the lining fabric 12. There are no weft threads in the inner pile section 13. Here, as shown in Figures 3 and 4, the surfaces of the outer fabric 11 and the inner fabric 12 have parallel uneven surfaces 11a and 12a arranged in the warp direction, respectively.
[0024] The pile fabric 10 of this embodiment is used as various fabrics such as bedding, and is bulky due to the presence of uneven parts 11a and 12a, and the inner pile part 13 having a large void structure consisting only of pile warp threads P1 and P2. Furthermore, because it has many air pockets inside, it easily traps air and has excellent heat retention, as well as excellent breathability, flexibility, and moisture absorption. In addition, because the surface is made of gauze-like outer fabric 11 and inner fabric 12, it has a cool texture. Because it possesses both heat retention and cooling properties, it is suitable for use throughout all four seasons. Because the interior has a simple structure consisting only of pile warp threads, it requires less material, is relatively easy to manufacture, and allows for lower manufacturing costs, including material costs.
[0025] As shown in Figure 1, in odd-numbered reeds, the first pile warp thread P1 of the inner pile section 13 is passed through the ground weft threads 1 to 5 of the surface fabric 11, on the inside for ground weft thread 1, on the outside for ground weft thread 2, on the inside for ground weft thread 3, on the outside for ground weft thread 4, and on the inside for ground weft thread 5, before being carried over to the backing fabric 12. Next, the first pile warp thread P1 is passed through the ground weft threads 10 to 14 of the backing fabric 12, on the inside for ground weft thread 10, on the outside for ground weft thread 11, on the inside for ground weft thread 12, on the outside for ground weft thread 13, and on the inside for ground weft thread 14, before being stretched across to the front fabric 11. Ground weft threads 6-9 and 15-18 are skipped, and the first pile warp thread P1 is not entangled. In the pile fabric 10 of this embodiment, the same arrangement is repeated in the odd-numbered reeds, with the ground weft yarns 1 to 18 forming one unit.
[0026] As shown in Figure 2, in the even-numbered reeds, the second pile warp thread P2 of the inner pile section 13 is passed through the ground weft threads 1 to 5 of the backing fabric 12, on the inside for ground weft thread 1, on the outside for ground weft thread 2, on the inside for ground weft thread 3, on the outside for ground weft thread 4, and on the inside for ground weft thread 5, before being stretched across to the outer fabric 11. Next, the second pile warp thread P2 is passed through the ground weft threads 10 to 14 of the outer fabric 11, on the inside for ground weft thread 10, on the outside for ground weft thread 11, on the inside for ground weft thread 12, on the outside for ground weft thread 13, and on the inside for ground weft thread 14, before being carried over to the backing fabric 12. Ground weft threads 6-9 and 15-18 are skipped, and the second pile warp thread P2 is not entangled. In the pile fabric 10 of this embodiment, the same arrangement is repeated in the even-numbered reeds, with the ground weft yarns 1 to 18 forming one unit.
[0027] As shown in Figures 1 and 2, in the pile fabric 10 of the embodiment, the first pile warp thread P1 and the second pile warp thread P2 are intertwined with the ground weft thread in a zigzag pattern. Furthermore, as shown in both figures, the zigzag pattern is symmetrical between the first pile warp thread P1 and the second pile warp thread P2.
[0028] Here, the first pile warp yarn P1 and the second pile warp yarn P2 of the inner pile portion 13 are made of elastic yarn (elastic fiber yarn). The elastic yarn is not particularly limited, but examples include polyurethane elastic yarn (spandex) and natural rubber yarn, and may be one that exhibits elasticity (shrinkability) when heated. In this embodiment, the first pile warp yarn P1 and the second pile warp yarn P2 are made of the same type of elastic yarn. On the other hand, the weft and warp threads of the outer fabric 11 and the lining fabric 12 are both made of non-elastic yarn (non-elastic fiber yarn). Non-elastic yarn here refers to yarn other than elastic yarn and is not particularly limited, but generally understood to be yarn that does not have significant elasticity, namely cotton, silk, linen, polyester, nylon, acrylic, and rayon.
[0029] As shown in Figure 3, due to the elasticity of the first pile warp threads P1 and the second pile warp threads P2 of the inner pile section 13, uneven surfaces 11a and 12a are naturally formed on the surfaces of the outer fabric 11 and the inner fabric 12, parallel to each other in the warp direction. In other words, in Figures 1 and 2, the portions of the ground wefts 1 to 5 and 10 to 14 of the surface fabric 11 and back fabric 12, which are constrained by the entanglement of the first pile warp thread P1 or the second pile warp thread P2, have their outward expansion restricted, resulting in the concave shape shown in Figure 3. Furthermore, when the first pile warp thread P1 or the second pile warp thread P2 is skipped, the portions of the ground weft threads 6 to 9 and ground weft threads 15 to 18 of the outer fabric 11 and lining fabric 12 that are not restrained can bulge outward, forming the convex portion shown in Figure 3.
[0030] As shown in Figure 3, the phases of the uneven portions 11a and 12a in the outer fabric 11 and the lining fabric 12 coincide. That is, the convex portions and the concave portions face each other in the vertical direction (they are directly opposite each other). Furthermore, in both odd-numbered and even-numbered reeds, the above arrangement is repeated with the ground weft threads 1 to 18 as one unit, so the size and pitch of the uneven portions 11a in the outer fabric 11 and the size and pitch of the uneven portions 12a in the lining fabric 12 are uniform. As a result, the unevenness on both surfaces of the pile fabric 10 becomes symmetrical, and the unevenness is uniform on each surface, enhancing its aesthetic appeal.
[0031] Figure 4 shows a cross-sectional photograph of the pile fabric 10 according to the embodiment when it is actually woven. It can be confirmed that uneven surfaces 11a and 12a are formed on the surfaces of the outer fabric 11 and the inner fabric 12, that their phases coincide, and that the uneven surfaces 11a and 12a are uniform.
[0032] Here, we conducted breathability tests on the pile fabric shown in Figure 4 and a typical commercially available towel blanket, based on JIS L 1096 Method A (Fragile method). The test involved attaching 200mm x 200mm test specimens taken from pile fabric and towel blankets to a Frazier-type testing machine, drawing in air to a pressure of 125 Pa, measuring the airflow rate at that time, and then calculating the air permeability (cm²) from the airflow rate and test area. 3 / cm 2 This was done by calculating (s). As a result, it was confirmed that the breathability of pile fabric is approximately 2.5 times that of towel blankets.
[0033] The structure of the pile fabric 10 of the embodiment is as described above. Next, with reference to Figure 5, the manufacturing method of the pile fabric of the embodiment will be described.
[0034] First, prepare the outer fabric 11 and the lining fabric 12, which are woven from the ground weft and ground warp threads. The means of preparation are not particularly limited; for example, the outer fabric 11 and lining fabric 12 may be purchased from an external source or manufactured in-house. When manufacturing the outer fabric 11 and the lining fabric 12, it is preferable to weave them in parallel, one above the other, and beat the weft threads of each fabric simultaneously, as this doubles the production efficiency compared to weaving them individually.
[0035] Next, as shown in Figure 5(a), the outer fabric 11 and the backing fabric 12 are placed opposite each other vertically, and the first pile warp threads P1 and the second pile warp threads P2 are interwoven in a zigzag pattern between them to form an inner pile section 13, thereby creating a pre-woven fabric 10'. Here, the first pile warp yarn P1 and the second pile warp yarn P2 are made of yarn that develops elasticity (shrinkability) when heated. As shown in the diagram, the surfaces of the outer fabric 11 and the backing fabric 12 of the pre-woven fabric 10' are both nearly flat.
[0036] Furthermore, as shown in Figure 5(b), the entire pre-woven fabric 10' is heat-set (heat-processed) using a heater H or the like to give elasticity (shrinkability) to the first pile warp threads P1 and the second pile warp threads P2. As a result, the areas where the first pile warp threads P1 and the second pile warp threads P2 of the outer fabric 11 and the inner fabric 12 are joined become indented, and the areas where they are not joined become relatively raised, causing uneven surfaces 11a and 12a to appear on both surfaces. Thus, the pile fabric 10 of the embodiment is completed. Since the pile fabric is completed using a simple two-step manufacturing method consisting of a weaving process and a heating process, manufacturing costs can be reduced.
[0037] The embodiments disclosed herein are illustrative in all respects and are not restrictive. The scope of the present invention is defined by the claims and includes all modifications and variations within the scope of the claims and in the sense equivalent thereto.
[0038] The number of ground weft threads skipped in the first pile warp thread P1 and the second pile warp thread P2 is not limited to this embodiment and can be set as appropriate. If the number of skipped threads is large, the protrusions of the uneven parts 11a and 12a of the outer fabric 11 and lining fabric 12 become larger (wider), and if the number of skipped threads is small, the protrusions of the uneven parts 11a and 12a of the outer fabric 11 and lining fabric 12 become smaller (narrower). In this embodiment, the number of weft threads skipped (pitch) between the first pile warp thread P1 and the second pile warp thread P2 is kept constant, but the number of skipped threads can also be made irregular or varied in different sections.
[0039] Regarding the joint between the inner pile section 13 and the outer fabric 11 and the lining fabric 12, the number of ground weft threads that intertwine the first pile warp threads P1 and the second pile warp threads P2 is not particularly limited. If the number of ground weft threads used for joining is large, the recesses of the uneven parts 11a and 12a of the outer fabric 11 and lining fabric 12 will become larger (wider), and if the number of threads used is small, the recesses of the uneven parts 11a and 12a of the outer fabric 11 and lining fabric 12 will become smaller (narrower).
[0040] By adjusting the elasticity of the first pile warp thread P1 and the second pile warp thread P2, the depth of the irregularities in the irregularities of In other words, if highly elastic yarns are used as the first pile warp yarn P1 and the second pile warp yarn P2, the shrinkage force in the depressions is relatively large, resulting in a relatively large depth of the unevenness. Conversely, if less elastic yarns are used, the shrinkage force in the depressions is relatively small, resulting in a relatively small depth of the unevenness.
[0041] In this embodiment, the uneven portions 11a and 12a of the outer fabric 11 and the inner fabric 12 are symmetrical (the phases of the convex portions and concave portions coincide), but the embodiment is not limited to this. For example, the convex and concave parts on both surfaces can be offset so that the phases of the convex parts of the outer fabric 11 and the concave parts of the lining fabric 12 coincide, or the size of the convex and concave parts on the outer fabric 11 and the lining fabric 12 can be made different. In this embodiment, the pile warp threads of the inner pile section 13 consist of a first pile warp thread P1 and a second pile warp thread P2, and there are two types of zigzag patterns. However, it is also possible to have only one type of zigzag pattern, or conversely, three or more types of zigzag patterns.
[0042] Thus, the zigzag pattern of the pile warp threads P1 and P2 of the inner pile portion 13, and the patterns of the uneven portions 11a and 12a of the outer fabric 11 and inner fabric 12 based thereon, are not limited to this embodiment and include a variety of patterns. In this embodiment, the first pile warp yarn P1 and the second pile warp yarn P2 of the inner pile portion 13 are made of the same type of elastic yarn, but they can also be made of different types and different thicknesses (count, denier, decitex).
[0043] In this embodiment, the outer fabric 11 and the lining fabric 12 are made of gauze, but the embodiment is not limited to this. The weaving method is also not limited to plain weave. In this embodiment, although not particularly limited, the outer fabric 11 and the lining fabric 12 can be the same color, or they can be different colors, such as the outer fabric 11 being a dark color and the lining fabric 12 being white. In this embodiment, the warp threads of the outer fabric 11 and the lining fabric 12 are made of non-elastic yarn, but they can also be made of elastic yarn. Including this, the warp and weft threads can be made of different types and thicknesses of yarn. The weft and warp threads can be subjected to special processing to add functions such as antibacterial, deodorizing, flame-retardant, water-repellent, and antistatic properties as appropriate. [Explanation of Symbols]
[0044] 10 Pile fabrics of the embodiment 10' Prewoven fabric 11 Outer cloth 11a Uneven part 12 Lining 12a Uneven part 13. Inner pile section 1-18 Ground weft threads P1 First pile warp P2 Second pile warp H heater
Claims
1. The surface fabric is woven from ground warp threads and ground weft threads, and the ground warp threads are made of non-elastic yarns. It is woven from ground warp threads and ground weft threads, and the ground warp threads are made of non-elastic yarns, The fabric comprises an inner pile section consisting only of pile warp threads that intertwine in a zigzag pattern at regular intervals with the parallel ground weft threads of the outer fabric and the parallel ground weft threads of the lining fabric, The pile warp threads of the inner pile portion are made of elastic yarn, and the shrinkage of these threads forms parallel, warp-like irregularities on the surfaces of the outer fabric and the inner fabric in the warp direction, in a pile fabric.
2. The pile fabric according to claim 1, wherein the pile warp threads of the inner pile portion are heat-shrinkable, and shrinkage due to heat processing forms parallel irregularities in the warp direction on the surfaces of the outer fabric and the backing fabric.
3. The pile fabric according to claim 1 or 2, wherein the pile warp of the inner pile portion consists of a first pile warp and a second pile warp, the first pile warp and the second pile warp are arranged alternately in parallel in the weft direction, the zigzag pattern formed by entanglement with the ground weft is symmetrical, and the phases of the unevenness formed on the surface of the outer fabric and the back fabric coincide.
4. The pile fabric according to claim 3, wherein the unevenness of the surface fabric and the unevenness of the back fabric are uniform.
5. The pile fabric according to claim 1 or 2, wherein the outer fabric and the inner fabric are gauze fabric.
6. The process involves preparing a front fabric woven from ground warp threads and ground weft threads, wherein the ground warp threads are made of non-elastic yarns, and a back fabric woven from ground warp threads and ground weft threads, wherein the ground warp threads are made of non-elastic yarns. The process involves intertwining pile warp threads made of elastic yarn in a zigzag pattern at regular intervals between the parallel ground weft threads of the outer fabric and the parallel ground weft threads of the lining fabric, between the opposing outer fabric and lining fabric. A method for manufacturing a pile fabric, comprising the step of shrinking the pile warp threads by heat processing to form parallel irregularities in the warp direction on the surfaces of the front fabric and the back fabric.
7. The process of preparing the outer fabric and lining fabric is as follows: A method for manufacturing a pile fabric according to claim 6, comprising weaving the aforementioned surface fabric and backing fabric in parallel, one above the other, and simultaneously beating a pair of upper and lower ground weft threads with a reed.