Dough manufacturing method

Abstract

The present invention provides a method for manufacturing fabrics that have the appearance of woven fabric and are lightweight. [Solution] The method for manufacturing the fabric includes the steps of setting a nylon composite yarn as the weft in the weft setting section of a weft-insertion type warp knitting machine, and setting the warp yarn in the warp setting section of the weft-insertion type warp knitting machine.

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a fabric as an example of a fabric.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Since a fabric is manufactured by alternately weaving warp threads and weft threads, in order to suppress the transparency of the fabric and increase the strength of the fabric, it is necessary to increase the density of the warp threads and the weft threads. Since a large amount of warp threads and weft threads are used in a fabric, there is still room for improvement in terms of weight reduction.

[0005] An object of the present invention is to provide a method for manufacturing a fabric having an appearance like a fabric and being lightweight.

Means for Solving the Problems

[0006] The method for manufacturing a fabric according to the first aspect of the present invention includes a step of setting a nylon composite yarn as a weft yarn in a weft yarn setting portion of a weft insertion warp knitting machine, and a step of setting a warp yarn in a warp yarn setting portion of the weft insertion warp knitting machine.

[0007] According to the above fabric manufacturing method, since the fabric is manufactured using a weft-insertion warp knitting machine, a fabric with a woven appearance can be obtained. A weft-insertion warp knitting machine manufactures fabric by intertwining the weft threads with the warp threads. Therefore, transparency is suppressed in the manufactured fabric even at low density. In addition, the manufactured fabric has high strength. Furthermore, the nylon composite yarn used as the weft has high elasticity. Therefore, when no stretching external force is acting on the fabric, the nylon composite yarn expands to fill the gaps with the warp threads more than when a stretching external force is acting on the fabric. Therefore, transparency of the fabric is suppressed.

[0008] According to the above method for manufacturing the fabric, it is possible to have a fabric-like appearance and to reduce the weight of the fabric.

[0009] A method for manufacturing a fabric according to a second aspect of the present invention is a method for manufacturing a fabric according to a first aspect, wherein the material constituting the warp threads is a synthetic fiber (excluding polyurethane) or a natural fiber.

[0010] According to the fabric manufacturing method described above, lightweight materials are used for the warp threads, making the fabric even lighter.

[0011] A method for manufacturing a fabric according to a third aspect of the present invention is a method for manufacturing a fabric according to the first or second aspect, wherein the warp threads are synthetic fibers, the weft threads are thicker than the warp threads, and the difference between the thickness of the weft threads and the thickness of the warp threads is in the range of 25 denier or more and 130 denier or less.

[0012] In the production of fabrics using a weft-inserted warp knitting machine, for example, if the thickness of the weft threads and the warp threads are the same, a pattern is easily formed in the fabric, and vertical lines are more likely to appear. On the other hand, if the weft threads are too thick compared to the warp threads, there is a risk of a pattern being formed in the fabric. According to the above fabric manufacturing method, the weft threads are thicker than the warp threads, and the difference in thickness between the weft threads and the warp threads is sufficiently small. Therefore, vertical lines and pattern creases are less likely to form in the fabric.

[0013] A method for manufacturing a fabric according to the fourth aspect of the present invention is a method for manufacturing a fabric according to the first or second aspect, wherein the warp threads are natural fibers, the weft threads are thicker than the warp threads, and the difference between the thickness of the weft threads and the thickness of the warp threads is within a range of count difference corresponding to 25 denier or more and 130 denier or less.

[0014] In the production of fabrics using a weft-inserted warp knitting machine, for example, if the thickness of the weft threads is the same as that of the warp threads, a pattern is likely to form in the fabric, and vertical lines are more likely to appear. On the other hand, if the weft threads are too thick compared to the warp threads, there is a risk of a pattern forming in the fabric. According to the above fabric manufacturing method, the weft threads are thicker than the warp threads, and the difference in thickness between the weft threads and warp threads is sufficiently small. Therefore, vertical lines and pattern formations are less likely to form in the fabric.

[0015] A method for manufacturing a fabric according to the fifth aspect of the present invention is a method for manufacturing a fabric according to any one of the first to fourth aspects, which includes a fabric manufacturing step of knitting by intertwining the weft threads with the warp threads, wherein the fabric manufacturing step is carried out such that one repeat of the fabric includes a portion in which the weft threads are formed and a portion in which the weft threads are not formed.

[0016] In the above fabric manufacturing method, the fabric can be made lighter because each repeat includes a portion where no weft threads are formed.

[0017] A method for manufacturing a fabric according to the sixth aspect of the present invention is a method for manufacturing a fabric according to any one of the first to fifth aspects, wherein when the thickness of the nylon composite yarn is XA denier, in the step of setting the nylon composite yarn, a tension of XA × 3 (g) or less is applied to the nylon composite yarn.

[0018] For example, when the weft yarn is a nylon yarn, it is common to apply a tension about five times the thickness of the weft yarn so that the weft yarn does not slacken. On the other hand, in the method for manufacturing the fabric, since the weft yarn is a nylon composite yarn, the weft yarn has high stretchability. Therefore, in the step of setting the nylon composite yarn as the weft yarn in the weft yarn setting section, the tension applied to the weft yarn can be set low. Thus, for example, in the step of dyeing the manufactured fabric, the shrinkage in the lateral direction of the fabric can be easily controlled.

[0019] The method for manufacturing a fabric according to the seventh aspect of the present invention is the method for manufacturing a fabric according to any one of the first aspect to the sixth aspect, and further includes a dyeing step of dyeing the fabric manufactured by the weft-inserting warp knitting machine, and a final setting step carried out after the dyeing step. In the final setting step, the setting temperature is within the range of 120°C or more and 140°C or less, and the setting speed is within the range of 20 m / min or less.

[0020] According to the method for manufacturing a fabric described above, in the final setting step, the load on the weft yarn and the warp yarn can be reduced, and the shrinkage rate of the fabric can be easily controlled. Thus, the quality of the fabric, particularly the stretchability, is stabilized.

Effects of the Invention

[0021] According to the method for manufacturing a fabric of the present invention, a fabric having an appearance like a cloth and being lightweight can be manufactured.

Brief Description of the Drawings

[0022] [Figure 1] A block diagram showing an example of the configuration of a weft-inserting warp knitting machine used in the method for manufacturing a fabric of the embodiment. [Figure 2] A flowchart showing an example of the method for manufacturing a fabric of the embodiment.

Modes for Carrying Out the Invention

[0023] <1. Embodiment> Hereinafter, an embodiment of a method for manufacturing a fabric according to the present invention will be described with reference to the drawings.

[0024] FIG. 1 is a block diagram showing an example of the configuration of a weft-inserting warp knitting machine 10 used in the method for manufacturing a fabric of the present embodiment. The weft-inserting warp knitting machine 10 includes a weft set part 11, a warp set part 12, and a fabric manufacturing part 13. As the weft-inserting warp knitting machine 10, a known one can be used. In the present embodiment, a weft-inserting warp knitting machine manufactured by KARL MAYER is used as the weft-inserting warp knitting machine 10.

[0025] The weft set part 11 is inserted with a nylon composite yarn as the weft. The nylon composite yarn is a combination of two or more different nylon fibers artificially combined. The weft of the present embodiment is a nylon composite yarn in which nylon 6 and nylon 56 are combined.

[0026] The warp set part 12 is inserted with the warp. The material constituting the warp can be arbitrarily selected. The material constituting the warp is, for example, a synthetic fiber or a natural fiber. The synthetic fiber is, for example, nylon, polyester, polypropylene, or polyethylene. The natural fiber is cotton, wool, a blended yarn or composite yarn of long fibers and short fibers including these. From the viewpoint of reducing the weight of the fabric, it is preferable that the material constituting the warp does not contain polyurethane.

[0027] The fabric manufacturing part 13 manufactures a fabric by winding the weft around the warped warp and knitting. Therefore, the fabric manufactured by the weft-inserting warp knitting machine 10 has an appearance like a woven fabric, more specifically, a piece of cloth. In addition, since the weft-inserting warp knitting machine 10 winds the weft around the warp to manufacture the fabric, the manufactured fabric has a lower density than a general woven fabric. Since the amount of yarn required for the fabric can be reduced, the weight of the fabric can be reduced. In addition, since the density of the fabric is low, the air permeability is high.

[0028] [[ID=**20**]] The relationship between the thickness of the weft yarn and the thickness of the warp yarn can be arbitrarily selected. In the production of fabric using a weft-inserted warp knitting machine 10, for example, if the thickness of the weft yarn and the thickness of the warp yarn are the same, a pattern is more likely to form in the fabric structure, and vertical lines are more likely to appear. For this reason, it is preferable that the thickness of the weft yarn is thicker than the thickness of the warp yarn. From the viewpoint of suppressing the formation of pattern patterns and vertical lines in the fabric, if the warp yarn is made of synthetic fibers, it is preferable that the difference between the thickness of the weft yarn and the thickness of the warp yarn is a count difference equivalent to 25 denier or more.

[0029] On the other hand, if the weft threads are too thick compared to the warp threads, there is a risk of pattern distortion forming in the fabric. From the viewpoint of suppressing the formation of pattern distortion in the fabric, when the warp threads are made of synthetic fibers, it is preferable that the difference in thickness between the weft threads and the warp threads is 130 denier or less. From the viewpoint of suppressing the formation of pattern distortion in the fabric, when the warp threads are made of synthetic fibers, it is preferable that the difference in thickness between the weft threads and the warp threads is a count difference equivalent to 130 denier or less.

[0030] When the warp threads are synthetic fibers, the preferred range for the difference between the thickness of the weft threads and the warp threads is 25 denier or more and 130 denier or less. When the warp threads are natural fibers, the preferred range for the difference between the thickness of the weft threads and the warp threads is a count difference that corresponds to the range of 25 denier or more and 130 denier or less.

[0031] Figure 2 is a flowchart showing an example of a fabric manufacturing method. The fabric manufacturing method includes a weft setting process, a warp setting process, a fabric manufacturing process, a pre-setting process, a dyeing process, and a final setting process. The fabric manufacturing method may omit any processes other than the weft setting process and the warp setting process, and may include any other processes in addition to those shown in Figure 2. In other words, the fabric manufacturing method only needs to include at least the weft setting process and the warp setting process. Furthermore, the order of each process can be changed as long as it is not technically inconsistent.

[0032] In the weft setting process of step S11, the worker sets the nylon composite yarn as the weft in the weft setting section 11. In the weft setting process, it is preferable to apply a predetermined tension to the weft so that it does not become loose. The tension applied to the weft in the weft setting process can be arbitrarily selected. In this embodiment, when the thickness of the nylon composite yarn is XA denier, a tension of XA × 3 (g) or less is applied to the nylon composite yarn in the weft setting process.

[0033] The warp setting process in step S12 is performed before or after the weft setting process. In the warp setting process, the worker sets the warp threads in the warp setting section 12. The warp setting process may be performed in parallel with the weft setting process.

[0034] The fabric manufacturing process in step S13 is carried out after the weft setting process and the warp setting process. In the fabric manufacturing process, the fabric manufacturing unit 13 manufactures the fabric by weaving the weft threads into the warped warp threads.

[0035] Step S14, the pre-setting process, is performed after the fabric manufacturing process and before the dyeing process. The pre-setting process involves heat-treating the fabric to determine its width.

[0036] The dyeing process in step S15 is carried out after the pre-setting process. The dyeing process is the process of dyeing the fabric produced by the weft-inserted warp knitting machine 10 to a predetermined color.

[0037] The final setting process in step S16 is performed after the dyeing process. The final setting process is a process in which the fabric is heat-treated to stabilize the shape of the product. The setting temperature and setting speed in the final setting process can be arbitrarily selected. From the viewpoint of reducing the load on the weft and warp threads and from the viewpoint of easily controlling the shrinkage rate of the fabric, the setting temperature is preferably in the range of 120°C to 140°C. From a similar viewpoint, the setting speed is preferably in the range of 20 m / min or less.

[0038] <2. Effects of this embodiment> The following effects can be obtained by the fabric manufacturing method of this embodiment.

[0039] <2-1> According to the fabric manufacturing method of this embodiment, since the fabric is manufactured using a weft-insertion warp knitting machine 10, a fabric with the appearance of woven fabric can be obtained. The weft-insertion warp knitting machine 10 manufactures the fabric by intertwining the weft threads with the warp threads. Therefore, transparency is suppressed in the manufactured fabric even when the density is low. In addition, the manufactured fabric has high strength. Furthermore, the nylon composite yarn used as the weft has high elasticity. Therefore, when no stretching external force is acting on the fabric, the nylon composite yarn expands to fill the gaps with the warp threads more than when a stretching external force is acting on the fabric. Therefore, transparency of the fabric is suppressed.

[0040] According to the fabric manufacturing method of this embodiment, the fabric has an appearance similar to woven fabric and can be made lighter.

[0041] <2-2> In this embodiment, the fabric manufacturing method does not use polyurethane as the warp thread, resulting in lightweight warp threads. Therefore, the fabric can be made even lighter.

[0042] <2-3> According to the fabric manufacturing method of this embodiment, the weft threads are thicker than the warp threads, and the difference in thickness between the weft threads and the warp threads is sufficiently small. Therefore, vertical lines and pattern distortions are less likely to form in the fabric.

[0043] <2-4> When the weft is made of nylon, it is common practice to apply a tension of about five times the thickness of the weft during the weft setting process to prevent the weft from becoming loose. However, in the fabric manufacturing method of this embodiment, the weft is made of nylon composite yarn, which has high elasticity. Therefore, the tension applied to the weft during the weft setting process can be set lower. As a result, for example, the lateral shrinkage of the fabric can be easily controlled during the dyeing process.

[0044] <2-5> In the final setting process, the setting temperature is within the range of 120°C to 140°C, and the setting speed is within the range of 20 m / min or less. In the final setting process, the load on the weft and warp threads can be reduced, and the shrinkage rate of the fabric can be easily controlled. As a result, the quality of the fabric, especially its elasticity, is stabilized.

[0045] <2-6> Because the weft is a nylon composite yarn, the pre-setting, dyeing, and final setting processes can be carried out at lower temperatures than when the weft is, for example, a non-composite nylon yarn, a nylon processed yarn (a yarn whose crimpability is achieved by twisting rather than a composite structure), or a polyester composite fiber. For this reason, the fabric manufacturing method of this embodiment makes it less likely for wrinkles to form in the fabric.

[0046] <3. Variant> The embodiments described above are illustrative of possible forms of the fabric manufacturing method according to the present invention and are not intended to limit its form. The fabric manufacturing method according to the present invention may take forms different from those illustrated in the embodiments. One example is a form in which some of the components of the embodiments are replaced, modified, or omitted, or a form in which new components are added to the embodiments. Several examples of modifications of the embodiments are shown below. Note that the following modifications can be combined with each other to the extent that they are not technically contradictory.

[0047] <3-1> In the above embodiment, the dyeing process was carried out after the weft setting process and the warp setting process. However, the dyeing process may be a process of dyeing the yarn itself before warping. That is, in this modified example, the dyeing process may be carried out before the weft setting process and the warp setting process.

[0048] <3-2> In the above embodiment, the fabric manufacturing process can be modified. For example, the fabric manufacturing process may be carried out such that one repeat of the fabric includes a portion where weft threads are formed and a portion where weft threads are not formed. For example, if the number of weft threads in one repeat of the fabric is 18, the number of weft threads in the portion where weft threads are formed and the number of virtual weft threads in the portion where weft threads are not formed are each factors of 18 (excluding 18), and their sum is 18. In another example, if the number of weft threads in one repeat of the fabric is 24, the number of weft threads in the portion where weft threads are formed and the number of virtual weft threads in the portion where weft threads are not formed are each factors of 24 (excluding 24), and their sum is 24. The fabric may also be composed entirely of portions where weft threads are formed in one repeat.

[0049] <3-3> In the above embodiment, at least one of the dyeing step and the final setting step can be omitted. [Explanation of Symbols]

[0050] 10: Weft-inserted warp knitting machine 11: Weft thread setting section 12: Warp thread setting section

Claims

1. The process involves setting nylon composite yarn as the weft in the weft setting section of a warp knitting machine with weft insertion, The process includes setting the warp threads in the warp thread setting section of the aforementioned weft-insertion type warp knitting machine. A method for manufacturing dough.

2. The material constituting the warp threads is a synthetic fiber (excluding polyurethane) or a natural fiber. A method for producing the dough according to claim 1.

3. The warp threads are synthetic fibers. The weft thread is thicker than the warp thread. The difference between the thickness of the weft thread and the thickness of the warp thread falls within the range of 25 denier to 130 denier. A method for producing the dough according to claim 1 or 2.

4. The aforementioned warp threads are natural fibers, The weft thread is thicker than the warp thread. The difference between the thickness of the weft yarn and the thickness of the warp yarn falls within the range of yarn count difference corresponding to a range of 25 denier to 130 denier. A method for producing the dough according to claim 1 or 2.

5. This process includes a fabric manufacturing step in which the weft threads are interwoven with the warp threads and knitted, The fabric manufacturing process is carried out such that, in one repeat of the fabric, there is a portion where the weft thread is formed and a portion where the weft thread is not formed. A method for producing the dough according to claim 1 or 2.

6. When the thickness of the aforementioned nylon composite yarn is set to XA denier, In the process of setting the nylon composite yarn, a tension of XA × 3 (g) or less is applied to the nylon composite yarn. A method for producing the dough according to claim 1 or 2.

7. A dyeing process for dyeing the fabric produced by the aforementioned weft-insertion warp knitting machine, The process further includes a final setting step performed after the aforementioned dyeing step, In the aforementioned final setting process, The set temperature is within the range of 120°C to 140°C. The set speed falls within the range of 20 m / min or less. A method for producing the dough according to claim 1 or 2.

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