Method for manufacturing clothing fabrics, and clothing fabrics

Abstract

To provide a method for manufacturing garment fabrics with improved elasticity, and garment fabrics. [Solution] The method for manufacturing garment fabric is characterized by comprising: a defibration step S2 in which raw material C is dry-fibred to produce fibers F; a mixing step S3 in which an elastic treatment agent T is mixed with the fibers F obtained in the defibration step S2 to produce a mixture; a deposition step S4 in which the mixture is deposited in air onto a breathable and elastic fabric N1 which will become the first layer L1 to produce a web W which will become the second layer L2; and a molding step S6 in which the fabric N1 and web W are stacked and molded by heating and pressurizing.

Description

[Technical Field]

[0001] This invention relates to a method for manufacturing garment fabrics and garment fabrics. [Background technology]

[0002] In recent years, technologies for reusing used clothing and other materials have been explored to address issues such as resource depletion and increasing waste. For example, Patent Document 1 discloses a method for producing fiber sheets by dry-processing the defibration of fabric. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-111178 [Overview of the project] [Problems that the invention aims to solve]

[0004] However, the manufacturing method described in Patent Document 1 had the problem of difficulty in improving the elasticity of the fiber sheet. Specifically, when fiber sheets are used in clothing, relatively high elasticity is required. These fiber sheets are based on the reuse of unspecified materials such as scraps and used clothing. Therefore, it was difficult to improve the elasticity of the fiber sheet, which may have limited its use as a fabric for clothing. In other words, there was a need for a manufacturing method for clothing fabrics that could improve elasticity. [Means for solving the problem]

[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 the fibers obtained in the defibration step with an elastic treatment agent to produce a mixture; a deposition step of depositing the mixture in air onto a breathable and elastic fabric to form a first layer to form a web, which will be a second layer; and a molding step of stacking the fabric and the web and molding them by heating and pressurizing them.

[0006] The garment fabric is characterized by comprising a first layer having breathability and elasticity, and a second layer superimposed on the first layer, in which an elastic treatment agent and fibers are deposited. [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] Enlarged schematic diagram showing the state of fibers and treatment agents in the second layer. [Figure 3] A schematic cross-sectional view showing other forms of clothing fabric. [Figure 4] A flowchart illustrating a method for manufacturing garment fabric according to an embodiment. [Figure 5] A schematic diagram showing the configuration of a garment fabric manufacturing apparatus. [Figure 6] A table showing details and evaluation results of the examples and comparative examples. [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, the Z axis alone or mutually orthogonal coordinate axes, the XYZ axes, are included 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, and the +Z direction may also be referred to as upward, and the -Z direction as 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 CL1 according to this embodiment has a multilayer structure comprising a first layer L1 and a second layer L2. Garment fabric CL1 is an example of the garment fabric of the present invention and is manufactured by the garment fabric manufacturing method of the present invention. Garment fabric CL1 has improved elasticity and is therefore suitable for use in fabrics such as sportswear and work clothes.

[0010] In the garment fabric CL1, the first layer L1 and the second layer L2 are laminated in that order from bottom to top.

[0011] The thickness of the garment fabric CL1 is set appropriately according to the intended use and form of the garment to which it is applied. The thickness of the garment fabric CL1 is not particularly limited, but for example, it is set to 0.30 mm or more and 1.50 mm or less. This improves the flexibility and mechanical strength of the garment fabric CL1. Furthermore, since the first layer L1 is laminated onto the second layer L2, the mechanical strength of the garment fabric CL1 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 and the second layer L2 are laminated, i.e., the direction along the Z axis.

[0012] The first layer L1 is permeable. In this specification, permeability is defined by the amount of air passing through the test specimen according to the JIS permeability test (L1096 2010 8.26.1 Method A). In this specification, permeability means that the amount of air determined by the above test method is 10 cm³. 3 / cm 2 This refers to a duration of 1.5 seconds or more. The breathability of the first layer L1 is derived from the material of the first layer L1, fabric N1, which will be described later.

[0013] Since the first layer L1 has air permeability, when the first layer L1 is used on the human body side inside the clothing, the stuffiness during wearing can be suppressed and the wearing comfort is improved. Also, in the production of the clothing fabric CL1, by utilizing the air permeability of the first layer L1, the deposition of fibers and the like onto the first layer L1 can be promoted. Specifically, by sucking the air in which fibers and the like are dispersed through the first layer L1, the formation of a web containing fibers is promoted. The web becomes the second layer L2. The method for producing the clothing fabric CL1 will be described in the section on the method for producing the subsequent clothing fabric.

[0014] The first layer L1 has elasticity. In this specification, elasticity is defined by the elongation rate of a test piece obtained by the JIS fabric and knitted fabric test method (L1096 2010 8,14,1 Method A). Having elasticity in this specification means that the elongation rate is 10% or more. The elongation rate of the first layer L1 is preferably 10% or more. Thereby, the elasticity of the clothing fabric CL1 is further improved. The elasticity of the first layer L1 is derived from the fabric N1 which is the material of the first layer L1.

[0015] The first layer L1 made of the fabric N1 preferably contains one or more of polyester (PE), polyurethane (PU), and polytrimethylene terephthalate (PTT). Specifically, the first layer L1 is preferably a woven fabric, a knitted fabric, or a non-woven fabric containing fibers composed of at least one of PU and PTT. According to this, the elasticity of the first layer L1 is further improved. The first layer L1 is not limited to being made of PU or PTT, and may contain other fibers or may be made of other fibers.

[0016] The fabric N may have elastic anisotropy. In this specification, elastic anisotropy means that the elongation rate varies depending on the direction of elongation, in other words, a difference occurs in the elongation rate depending on the direction of elongation. Although not particularly limited, the difference in elongation rate is, for example, about 10%. According to this, the direction used when processing the clothing can be defined, and the elasticity can be arbitrarily improved according to the part of the clothing.

[0017] Anisotropic stretchability may be imparted to fabric N1 by the weaving or knitting method. For example, when using a plain weave fabric as fabric N1, anisotropic stretchability may be imparted by changing the elongation rates of the warp and weft threads.

[0018] 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 mechanical strength of the garment fabric CL1.

[0019] The first layer L1 and the second layer L2 are bonded together by the binding action of the treatment agent that forms the material of the second layer L2. The first layer L1 may have an adhesive layer at its interface with the second layer L2, and may be in close contact with the second layer L2 through this adhesive layer.

[0020] The first layer L1 may be colored. If unspecified materials are reused for the second layer L2, the color of the first layer L1 and the second layer L2 may differ significantly. In this case, when the garment fabric CL1 is processed into a garment, the difference in color between the first layer L1 and the second layer L2 will be easily noticeable. Coloring the first layer L1 can mitigate this difference in color. Furthermore, when the first layer L1 is used on the outside of the garment, coloring the first layer L1 improves the design of the garment.

[0021] 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 at the stage of fabric N1 which will become the first layer L1, or it may be carried out during the manufacturing process of garment fabric CL1.

[0022] The second layer L2 is a nonwoven fabric containing multiple fibers obtained by defibrating a cloth or the like, and a treatment agent. The second layer L2 is superimposed on the first layer L1, and the treatment agent and the multiple fibers are deposited 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, a dry method refers to a process carried out in the air, such as the atmosphere, rather than in a liquid such as water.

[0023] Fibers are one of the main components of the second layer L2 and, along with the treatment agent, 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 scraps or 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.

[0024] When unspecified materials such as scraps and used clothing are used as fiber materials, there is a possibility that fibers of various materials will be mixed in the second layer L2. Depending on the material and form of the fibers, the elasticity of the formed second layer L2 may change. For this reason, it has been difficult to adjust the elasticity of the second layer L2 conventionally. In contrast, in garment fabric CL1, an elastic treatment agent is included in the second layer L2, so the elasticity of the second layer L2 is ensured.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] Considering the reuse of garments processed from garment fabric CL1, 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.

[0029] The basis weight of the second layer L2 is 100g / m². 2 More than 180g / m 2 The following is preferable: The basis weight of the second layer is 100 g / m². 2 As a result of the above, the basis weight of the garment fabric CL1 increases, further improving its elasticity. In addition, the tensile strength of the garment fabric CL1 is improved, and the surface condition when stretched is also improved. The basis weight of the second layer is 180 g / m². 2 The following conditions ensure the flexibility and suppleness of the CL1 garment fabric.

[0030] Furthermore, if the basis weight of the second layer L2 falls within the above range, a good balance between thinness and mechanical strength is achieved in the second layer L2. The basis weight of the second layer L2 is adjusted by the amount of web deposited during the deposition process when manufacturing the garment fabric CL1, i.e., the thickness of the web. Basis weight is the number of grams per square meter of surface area along the XY plane in a single piece of fabric.

[0031] 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 mechanical strength of the garment fabric CL1. 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 CL1.

[0032] As shown in Figure 2, in the second layer L2, the treatment agent T coats the fibers F and also connects the fibers F together. More specifically, the treatment agent T imparts elasticity to the second layer L2. In addition, the treatment agent T has a binding effect, bonding the fibers F together in the second layer L2. The treatment agent T is not limited to coating the entire surface of the fibers F, but may also coat only a portion of the fibers F. Furthermore, the treatment agent T may be included in the second layer L2 without coating the fibers F, but rather interposed between the fibers F.

[0033] The treatment agent T is made of a flexible resin. Examples of such resins include thermoplastic resins such as polyurethane and silicone, or thermosetting resins. One of these types may be used alone or in combination of two or more types in the treatment agent T.

[0034] The second layer L2 may contain other resins in addition to the treatment agent T. Examples of other 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)). These resins bond the fibers F together in the same way as the treatment agent T.

[0035] The second layer L2 may contain additives. Examples of additives include flame retardants, antioxidants, UV absorbers, flocculation inhibitors, antibacterial agents, antifungal agents, waxes, and mold release agents.

[0036] The second layer L2 may have a surface treatment or other pretreatment applied to the downward-facing surface or the upward-facing surface that is in contact with the first layer L1. Surface treatment improves various physical properties such as abrasion resistance. Surface treatment may be performed during the manufacturing process of the garment fabric CL1, or it may be performed separately after the garment fabric CL1 has been manufactured.

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

[0038] The garment fabric of the present invention is not limited to the two-layer garment fabric CL1 described above. The garment fabric of the present invention may also have the form of a three-layer garment fabric CL2 as described below.

[0039] As shown in Figure 3, the garment fabric CL2 has a multilayer structure comprising a first layer L1, a second layer L2, and a third layer L3. Garment fabric CL2 is an example of the garment fabric of the present invention and is manufactured by the garment fabric manufacturing method of the present invention. Garment fabric CL2 also has improved elasticity and is therefore suitable for use in fabrics such as sportswear and work clothes.

[0040] Clothing fabric CL2 differs from clothing fabric CL1 in that a third layer L3 is attached to the upper surface of the second layer L2. Therefore, the same symbols are used for components with the same structure as clothing fabric CL1, and redundant explanations are omitted.

[0041] In the garment fabric CL2, the first layer L1, the second layer L2, and the third layer L3 are layered in this order from bottom to top. When processing the garment fabric CL2 into clothing, either the first layer L1 or the third layer L3 is used on the outside of the garment.

[0042] The third layer L3 preferably has breathability and elasticity. The elasticity of the garment fabric CL2 may be improved by using an elastic woven fabric as the material for the third layer L3. In particular, if the elasticity of the woven fabric that becomes the third layer L3 is lower than that of the fabric N1 that becomes the first layer L1, and the third layer L3 is used on the outside of the garment, the surface condition when the garment is pulled will be good, and the appearance when stretched will be improved. The breathability and elasticity of the third layer L3 are derived from the woven fabric N3, which is the material of the third layer L3 and will be described later.

[0043] The third layer L3, which is the fabric N3, preferably contains one or more of polyester, polyurethane, and polymethylene terephthalate. Specifically, the third layer L3 is preferably a woven, knitted, or nonwoven fabric containing a fiber F consisting of at least one of PE, PU, ​​and PTT. The third layer L3 is not limited to the above fiber F, and may contain other fibers F, or may consist of other fibers F.

[0044] The thickness of the third layer L3 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 mechanical strength of the garment fabric CL2.

[0045] The third layer L3 and the second layer L2 are bonded together by the binding action of the treatment agent T that forms the material of the second layer L2. The third layer L3 may have an adhesive layer at its interface with the second layer L2, and may be in close contact with the second layer L2 through this adhesive layer.

[0046] The third layer L3 may be colored in the same way as the first layer L1 of the garment fabric CL1. Furthermore, the third layer L3 may have anisotropic stretch properties, similar to the first layer L1.

[0047] 2. Method for manufacturing garment fabrics The present invention provides an example of a method for manufacturing garment fabric CL2. The method for manufacturing garment fabric CL2 is an example and is not limited to the following configuration and sequence. The method for manufacturing garment fabric CL2 is also applicable to the manufacture of garment fabric CL1.

[0048] As shown in Figure 4, the method for manufacturing the garment fabric CL2 according to this embodiment comprises a raw material supply step S1, a defibration step S2, a mixing step S3, a deposition step S4, a bonding step S5, and a molding step S6. In the method for manufacturing the garment fabric CL2, the garment fabric CL2 is manufactured by going through each step in the order described above, from the upstream raw material supply step S1 to the downstream molding step S6.

[0049] A specific example of a method for manufacturing garment fabric CL2 will be explained along with a manufacturing apparatus 1 for producing garment fabric CL2. The manufacturing apparatus 1 described below is an example and is not limited to the configuration shown. In the manufacturing apparatus 1, the end of the conveying direction for raw materials, fabric N1, 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.

[0050] As shown in Figure 5, the 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 bonding unit 73, a molding unit 150, and a cutting unit 160, arranged from upstream to downstream. The manufacturing apparatus 1 is also equipped with a control unit 28 that comprehensively controls the operation of each of the above components.

[0051] 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 derived from scraps or used clothing.

[0052] The coarse crushing unit 10 shreds the raw material C supplied from the supply unit 5 into fine pieces in the air, such as the atmosphere. 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.

[0053] 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.

[0054] The defibration process S2 is performed in the defibration unit 30. The defibration unit 30 defibrates the fine fragments of the raw material C, which is a fabric, in a dry manner to generate and extract the fibers F 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 generating mechanism (not shown). The fine fragments of the raw material C are introduced into the defibration unit 30 through the inlet 31 by the airflow from the airflow generating mechanism.

[0055] 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.

[0056] The fibers F 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 F 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.

[0057] Although not shown in the diagram, the 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 F. Examples of separation mechanisms include known devices such as sieves. According to the separation mechanism, the impurity content is reduced, and high-purity fibers F can be used in the second layer L2. Then the process proceeds to the mixing step S3.

[0058] The mixing step S3 is performed in the mixing unit 60. The mixing unit 60 mixes the fibers F obtained in the defibration step S2 with the aforementioned treatment agent T and other components 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 F and treatment agent T are mixed in air to form a mixture. It is preferable that the mixture does not contain colorants. Here, "does not contain 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 F, or colorants that have been unintentionally mixed in.

[0059] The hopper 13 is connected to the inside of the pipe 40 via a supply pipe 61. In the supply pipe 61, a valve 65 is provided between the hopper 13 and the pipe 40. The hopper 13 supplies the treatment agent T into the pipe 40. The valve 65 adjusts the mass of the treatment agent T supplied from the hopper 13 to the pipe 40. This adjusts the mixing ratio of the fiber F and the treatment agent T.

[0060] Furthermore, in mixing step S3, it is preferable to mix the liquid containing the treatment agent T with the fibers F to form a mixture. Examples of the liquid containing the treatment agent T include a solution in which the treatment agent T is dissolved in a solvent, a dispersion in which the treatment agent T is dispersed in a dispersion medium, or a liquid obtained by melting the treatment agent T. As a result, the liquid containing the treatment agent T spreads wetly over the surface of the fibers F, making it easier for the elasticity of the treatment agent T to manifest in the second layer L2. Therefore, the elasticity, tensile strength, and surface condition when stretched are improved in the garment fabric CL2. The treatment agent T may be mixed with the fibers F in the form of powder, particulate matter, or fibers.

[0061] 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 resins and additives other than the treatment agent T into pipe 40. Valve 66 adjusts the mass of resins and additives other than the treatment agent T supplied from hopper 14 to pipe 40. This adjusts the mixing ratio of additives to fibers F and treatment agent T. Alternatively, resins and additives other than the treatment agent T may be mixed with the treatment agent T beforehand and supplied from hopper 13. Furthermore, if no resins or additives other than the treatment agent T are added to the mixture, hopper 14, supply pipe 62, and valve 66 may be omitted.

[0062] The fiber content in the second layer L2 is adjusted in the mixing step S3 by the mixing ratio of fiber F to other components including the treatment agent T. Specifically, in the web W, the mass ratio of fiber F to other components is in the range of 9:1 to 5:5. Although not particularly limited, in this embodiment, in order to improve the mechanical strength of the second layer L2, the fiber content in the web W is set to 65% by mass or more and 85% by mass or less.

[0063] When the origin of the fabric used as raw material C, such as scraps or used clothing, is clear, it is preferable to change the type of treatment agent T according to the material or weave of the fabric. This allows for adjustment of physical properties, including elasticity and tensile strength, in the garment fabric CL2.

[0064] The fibers F and other components, including the treatment agent T, are mixed as they are transported through the pipe 40 to the deposition section 100 to form a mixture. To promote mixing in the pipe 40 and 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 the deposition process S4.

[0065] The deposition process S4 is carried out in the deposition section 100. In the deposition section 100, the mixture is deposited in air onto a breathable and stretchable 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 CL1. In other words, the web W is formed by depositing a mixture containing defibrated fibers F and a treatment agent T, etc., 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.

[0066] 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.

[0067] 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.

[0068] 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 F as it rotates. The sieve section 101b allows fibers F and treatment agents T smaller than the mesh size of the sieve to pass from the inside to the outside. As a result, the mixture is dispersed into the air inside the housing section 102 after the tangled fibers F in the drum section 101 have been loosened.

[0069] The fabric supply unit 71 continuously feeds the roll-shaped fabric N1 onto the mesh belt 122. When using fabric N1 with an adhesive layer, the adhesive layer of the fabric N1 is positioned so that it faces upwards. This ensures that the adhesive layer and the web W are in contact. The elongation rate of the fabric N1 that forms the first layer L1 is 10% or more.

[0070] If the origin of the fabric used as raw material C, such as scraps or used clothing, is clear, it is preferable to change the material of fabric N1 according to the material or weave of the fabric. This allows for adjustment of physical properties, including elasticity and tensile strength, in the garment fabric CL2.

[0071] The mixture containing the fibers F is dispersed from the inside of the sieve section 101b into the air inside the housing section 102. Then, the mixture containing the fibers F randomly accumulates above the fabric N1 as it is conveyed on the mesh belt 122. As a result, the fibers F in the web W are less likely to be oriented in a particular direction.

[0072] The sieve section 101b does not necessarily have the function of separating large fibers F from the mixture. That is, the drum section 101 may loosen the fibers F 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.

[0073] The basis weight of the garment fabric CL2 is adjusted by the basis weight of fabric N1, the woven fabric N3 (described later), and the web W. In particular, the basis weight of the second layer L2 is adjusted by changing the weight per unit area of ​​the web W.

[0074] The basis weight of the second layer L2 can be changed by adjusting the amount of mixture deposited on the dough N1. Specifically, the amount of the mixture is changed by the rotation speed of the blade member 101a in the deposition process S4, the amount of mixture supplied to the deposition section 100 per hour, and the conveying speed of the dough N1 by the mesh belt 122. As mentioned above, the basis weight of the second layer L2 is 100 g / m². 2 More than 180g / m 2 The following is preferable.

[0075] Furthermore, in order to increase the basis weight of the second layer L2, the mixture may be deposited while stretching the fabric N1 during the deposition process S4. Specifically, tension is applied to the area directly below the housing portion 102 of the fabric N1 to stretch it. By depositing the mixture in this state and then releasing the tension, the basis weight of the web W increases. As a result, the basis weight of the second layer L2 increases, and the elasticity of the garment fabric CL2 is further improved. In addition, the tensile strength of the garment fabric CL2 increases, and the appearance when stretched is improved.

[0076] 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.

[0077] 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.

[0078] The multiple holes in the mesh belt 122 allow air to pass through but make it difficult for fibers F and treatment agents T contained in the mixture to pass through. The mesh belt 122 is an endless belt and is stretched by four tension rollers 121.

[0079] The mesh belt 122 moves downstream with its upper surface due to the rotation of the tension roller 121. 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. Then the process proceeds to the bonding process S5.

[0080] Here, a humidifier 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 F and treatment agents T contained in the web W. Alternatively, a water-soluble agent may be added to the water used for humidification, and surface treatment or the like may be applied to the web W, which will become the second layer L2, in parallel with the humidification.

[0081] The bonding process S5 is performed at the bonding section 73. After the deposition process S4 and before the molding process S6, the third layer L3, which will be the fabric N3, is bonded to the upper surface of the web W. As described above, it is preferable that the elasticity of the fabric N3 is lower than that of the fabric N1.

[0082] The fabric N3 is supplied from the fabric supply unit 72 to the adhesive unit 73. The fabric supply unit 72 continuously feeds the roll-shaped fabric N3 upwards on the web W. When using fabric N3 with an adhesive layer, the adhesive layer is brought into contact with the upper surface of the web W.

[0083] The adhesive section 73 adheres the upper surface of the web W to the lower surface of the fabric N3. The adhesive section 73 is a pair of pressure rollers that press the fabric N1 and web W against the fabric N3 from above and below. Note that when the garment fabric CL1 is manufactured by the manufacturing apparatus 1, the adhesive section 73 and the adhesive process S5 are omitted. Then the process proceeds to the molding process S6.

[0084] A dancer roller 141 is positioned between the bonding process S5 and the molding process S6. The dancer roller 141 ensures sufficient processing time for the downstream molding process S6. Specifically, the molding process S6 is a batch process. Therefore, by moving the dancer roller 141 up and down over the continuously transported fabric N1, web W, and woven fabric N3, sufficient processing time is ensured for the molding process S6. The fabric N1, web W, and woven fabric N3 are transported downstream via the dancer roller 141.

[0085] The molding process S6 is performed in the molding section 150. In the molding section 150, the fabric N1, web W, and woven fabric N3 are layered and molded by heating and pressurizing. When manufacturing the garment fabric CL1, the fabric N1 and web W are layered and molded by heating and pressurizing.

[0086] The molding unit 150 is a heating press device comprising an upper substrate 152 and a lower substrate 151. The upper substrate 152 and the lower substrate 151 pressurize the fabric N1, web W, and cloth N3 between them and heat them with a built-in heater. In the molding process S6, the molding process S6 may be performed continuously using a pair of heating rollers or the like. When a pair of heating rollers is used, the dancer roller 141 may be omitted.

[0087] The web W is compressed from above and below by pressure through the fabric N1 and woven fabric N3, increasing its density. Then, upon heating, the treatment agent T melts and spreads wet between the fibers F. When heating ends and the treatment agent T solidifies in this state, the fibers F are bonded together by the treatment agent T. In addition, the treatment agent T on the web W adheres the fabric N1 and woven fabric N3 to the web W. As a result, fabric N1 becomes the first layer L1, the web W becomes the second layer L2, and woven fabric N3 becomes the third layer L3.

[0088] The pressurization conditions in the molding section 150 are adjusted as appropriate depending on the desired density of the garment fabric CL2. For example, in molding step S6, the pressurization pressure is set to 0.01 MPa or higher. The heating conditions in the molding section 150 are adjusted as appropriate depending on the type of treatment agent T, its melting point, or curing temperature. For example, in molding step S6, the heating temperature is set to 90°C or higher.

[0089] In the molding section 150, a strip-shaped garment fabric CL2 is formed from the fabric N1, web W, and woven fabric N3, with these materials integrated together.

[0090] A cutting section 160 is located downstream of the molding section 150. The cutting section 160 shapes the edges of the strip-shaped garment fabric CL2 in the direction along the Y-axis. The cutting section 160 is equipped with a vertical blade (not shown). The vertical blade cuts the strip-shaped garment fabric CL2 along the conveying direction. As a result, the edges of both ends of the garment fabric CL2 are trimmed.

[0091] The strip-shaped garment fabric CL2 is then wound into a roll to form a bolt of fabric. Through the above manufacturing process, garment fabric CL2, including the first layer L1, the second layer L2, and the third layer L3, is produced.

[0092] According to this embodiment, the following effects can be obtained.

[0093] The elasticity of the garment fabrics CL1 and CL2 can be improved. Specifically, the elasticity of the second layer L2 is ensured by the treatment agent T. The elasticity of the garment fabrics CL1 and CL2 is enhanced by the first layer L1. As a result, even when reusing unspecified materials such as scraps or used clothing, garment fabrics CL1 and CL2 with improved elasticity can be manufactured. Therefore, a method for manufacturing garment fabrics with improved elasticity can be provided.

[0094] The elasticity of garment fabrics CL1 and CL2 can be improved. Specifically, the elasticity of the second layer L2 is ensured by the treatment agent T. The elasticity of garment fabrics CL1 and CL2 is enhanced by the first layer L1. As a result, even when reusing unspecified materials such as scraps or used clothing, the elasticity can be improved. Therefore, garment fabrics CL1 and CL2 with improved elasticity can be provided.

[0095] The following describes the conclusions drawn from the embodiment.

[0096] The 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 the fibers obtained in the defibration step with an elastic treatment agent to produce a mixture; a deposition step of depositing the mixture in air onto a breathable and elastic fabric to form a first layer to produce a web, which will be the second layer; and a molding step of stacking the fabric and web and molding them by heating and pressurizing them.

[0097] This configuration allows for improved elasticity of the garment fabric being manufactured. Specifically, the elasticity of the second layer is ensured by the treatment agent. The elasticity of the garment fabric is enhanced by the first layer. As a result, even when reusing unspecified materials such as scraps or used clothing, it is possible to manufacture garment fabric with improved elasticity. Therefore, a method for manufacturing garment fabric with improved elasticity can be provided.

[0098] In the above method for manufacturing garment fabric, the fabric has anisotropic elasticity.

[0099] With this configuration, because the elasticity is anisotropic, the elasticity can be arbitrarily improved depending on the part of the garment by defining the direction in which it is used.

[0100] In the above method for manufacturing clothing fabric, the fabric is stretched while the mixture is deposited during the deposition process.

[0101] According to this configuration, since the mixture is deposited while the fabric is in a stretched state, the basis weight of the clothing fabric increases and the elasticity is further improved. Also, in the clothing fabric, the tensile strength increases and the appearance when stretched is improved.

[0102] In the above method for manufacturing a clothing fabric, in the deposition step, the amount of the mixture deposited on the fabric is adjusted so that the basis weight of the second layer is 100 g / m 2 or more and 180 g / m 2 or less.

[0103] According to this configuration, since the basis weight of the second layer is 100 g / m 2 or more, the basis weight of the clothing fabric increases and the elasticity is further improved. Also, in the clothing fabric, the tensile strength increases and the surface state when stretched is improved. Since the basis weight of the second layer is 180 g / m 2 or less, the flexibility and suppleness of the clothing fabric are ensured.

[0104] In the above method for manufacturing a clothing fabric, in the mixing step, a liquid containing a treatment agent is mixed with the fibers.

[0105] According to this configuration, since the treatment agent spreads wet on the surface of the fibers, the elasticity of the treatment agent is likely to be exhibited in the second layer. Thereby, in the clothing fabric, the elasticity, tensile strength, and surface state when stretched are improved.

[0106] In the above method for manufacturing a clothing fabric, the fabric contains one or more of polyurethane and polyethylene terephthalate.

[0107] According to this configuration, since polyurethane and polyethylene terephthalate are relatively excellent in elasticity, the elasticity of the clothing fabric is further improved.

[0108] The above method for manufacturing a clothing fabric includes an attaching step of attaching a fabric that has lower elasticity than the fabric to the web as the third layer after the deposition step and before the forming step. In the forming step, the fabric, the web, and the fabric are overlapped and heated and pressed to form.

[0109] With this configuration, the third layer improves the tensile strength and surface condition when stretched in the garment fabric.

[0110] The above method for manufacturing garment fabrics involves changing the type of treatment agent or the fabric material depending on the material or weave of the fabric.

[0111] This configuration allows for the adjustment of physical properties, including elasticity and tensile strength, in clothing fabrics.

[0112] The garment fabric is characterized by comprising a first layer having breathability and elasticity, and a second layer superimposed on the first layer, in which an elastic treatment agent and fibers are deposited.

[0113] This configuration allows for improved elasticity. Specifically, the elasticity of the second layer is ensured by the treatment agent. The first layer enhances the elasticity of the garment fabric. As a result, even when reusing unspecified materials such as scraps or used clothing, elasticity can be improved. Therefore, it is possible to provide garment fabric with improved elasticity.

[0114] 3. Examples and Comparative Examples The effects of the above embodiments will be explained in more detail below with reference to examples and comparative examples. Figure 6 shows the composition of the garment fabrics and evaluation results for Examples 1 to 8 and Comparative Examples 1 to 3. In the following description, Examples 1 to 8 may be collectively referred to simply as "Examples," and Comparative Examples 1 to 3 may be collectively referred to simply as "Comparative Examples." It should be noted that the present invention is not limited in any way by the following examples.

[0115] 3.1. Preparation of fabric for evaluation garments As shown in Figure 6, the two-layer garment fabric CL1 from the above embodiment was applied to Examples 1 to 4. The three-layer garment fabric CL2 from the above embodiment was applied to Examples 5 to 8.

[0116] In Example 1, white cotton cloth was used as the raw material C for the second layer L2. Specifically, in the raw material supply process S1, the cloth C was roughly crushed into approximately rectangular pieces with a long side of 1 mm to 30 mm using a cutter mill from Makino Sangyo Co., Ltd. Next, the pieces were subjected to defibration in the same manner as in the defibration process S2 of the above embodiment to obtain fibers F.

[0117] Next, in mixing step S3, the fiber F and treatment agent T were mixed by air agitation in a mass ratio of 7:3. DIC Corporation's Boncoat® 4001 (acrylic resin emulsion) was used as the treatment agent T.

[0118] Next, in the deposition process S4, the above mixture was deposited on the surface of the fabric N1 in air to form the web W. At this time, the basis weight of the second layer L2 was 100 g / m². 2 The amount of mixture deposited was adjusted to achieve the desired result. As fabric N1, Uni Textile Co., Ltd.'s KKF5200-58 75d high-tension knit wide fabric with an elongation rate of 120% was used. The above elongation rate is the value measured by the method described above.

[0119] Next, the bonding process S5 for creating the three-layer structure was omitted, and the molding process S6 was carried out. In the molding process S6, the web W and fabric N1 were subjected to a heat press. At this time, an Itsumi AF-54TEN (product name) was used as the heat press, and the heating conditions were set to 150°C for 1 minute, resulting in a pressure condition in which the thickness of the second layer L2 was 0.31 mm. After that, the fabric was cut into single sheets measuring 300 mm in length and 50 mm in width using a cutter to prepare test pieces of the garment fabric CL1 of Example 1.

[0120] In Example 2, the basis weight of the second layer L2 was 180 g / m² compared to Example 1. 2 Except for the above, the procedure was carried out similarly to prepare a test specimen of the garment fabric CL1 of Example 2.

[0121] In Example 3, the treatment agent T was not in liquid form but mixed with the fiber F in fibrous solid form. Otherwise, the procedure was the same as in Example 1 to prepare a test specimen of the garment fabric CL1 of Example 3.

[0122] In Example 4, the basis weight of the second layer L2 was 180 g / m², compared to Example 3. 2 Except for the above, the procedure was carried out similarly to prepare a test specimen of the garment fabric CL1 of Example 2.

[0123] In Example 5, the deposition process up to step S4 was carried out in the same manner as in Example 1. Next, the bonding process S5 was performed. Specifically, Sunwell 41255 40d nylon coated stretch with an elongation rate of 130% was used as the fabric N3. The above elongation rate was measured using the method described above. After that, the molding process from step S6 onward was carried out in the same manner as in Example 1 to produce a test piece of the garment fabric CL2 of Example 5.

[0124] In Example 6, the basis weight of the second layer L2 was 180 g / m², compared to Example 5. 2 Except for the above, the procedure was carried out similarly to prepare a test specimen of the garment fabric CL2 of Example 6.

[0125] In Example 7, the treatment agent T was not in liquid form but mixed with the fiber F in fibrous solid form. Otherwise, the procedure was the same as in Example 5 to prepare a test specimen of the garment fabric CL2 of Example 7.

[0126] In Example 8, the basis weight of the second layer L2 was 180 g / m², compared to Example 7. 2 Except for the above, the procedure was carried out similarly to prepare a test specimen of the garment fabric CL2 of Example 8.

[0127] In Comparative Example 1, the first layer L1, fabric N1, was not used, and the garment fabric was prepared using only the second layer L2, which consisted of the web W. Other conditions were carried out in the same manner as in Example 1, and a test specimen of the garment fabric of Comparative Example 1 was prepared.

[0128] In Comparative Example 2, a two-layer structure similar to the garment fabric CL1 of the above embodiment was applied. However, in Comparative Example 2, a non-stretchable fabric was used for the first layer L1. Specifically, Uni Textile Co., Ltd.'s KKF3800-58 New Venus Suede wide width with an elongation rate of 3% was used as the fabric. The elongation rate of the fabric was measured using the method described above. Otherwise, the procedure was carried out in the same manner as in Example 1 to prepare a test piece of the garment fabric of Comparative Example 2.

[0129] In Comparative Example 3, a two-layer structure similar to that of the garment fabric CL1 in the above embodiment was applied. However, in Comparative Example 3, instead of using the stretchable treatment agent T, a commercially available fibrous urethane resin was applied. Otherwise, the procedure was carried out in the same manner as in Example 3 to prepare a test piece of the garment fabric of Comparative Example 3.

[0130] 3.2. Evaluation of Test Specimens For each test specimen in the examples and comparative examples, elongation, tensile strength, and surface condition during tensile testing were evaluated.

[0131] 3.2.1. Growth Rate As an indicator of elasticity, the elongation rate of the test specimens was measured using the JIS fabric testing method for woven and knitted fabrics (L1096 2010 8,14,1 A method) described above. The obtained elongation rates were evaluated according to the evaluation criteria below and are shown in Figure 6. Evaluation Criteria A: The growth rate is 25% or more. B: The growth rate is between 20% and 25%. C: The growth rate is between 15% and 20%. D: The growth rate is between 10% and 15%. E: The growth rate is less than 10%.

[0132] 3.2.2. Tensile Strength Similar to the elongation rate described above, the tensile strength was measured using the JIS standard fabric testing method for woven and knitted fabrics (L1096 2010 8,14,1 A method), and the maximum value at the time of fracture of the test specimen was defined as the tensile strength. The obtained tensile strengths were evaluated according to the evaluation criteria below and are shown in Figure 6. Evaluation Criteria A: The tensile strength is 160N or more. B: The tensile strength is 140N or more and less than 160N. C: The tensile strength is 120N or more and less than 140N. D: The tensile strength is 100N or more and less than 120N. E: The tensile strength is less than 100N.

[0133] 3.2.3. Surface condition under tension During the measurement of the elongation rate described above, the surface condition of the test specimen at approximately 10% elongation was visually observed and evaluated according to the evaluation criteria below, as shown in Figure 6. In the examples, the observation surface was the surface of the first layer L1 in the case of a two-layer structure, and the surface of the third layer L3 in the case of a three-layer structure. In the comparative examples, the surface condition of the test specimen immediately before fracture was observed. In Comparative Example 1, the observation surface was the surface corresponding to the second layer L2 formed from the web W, and in Comparative Examples 2 and 3, the observation surface was the surface corresponding to the first layer L1 of Example 1. A: It has a dense and intricate appearance. B: It has low density and a rough appearance. C: It has extremely low density and a very rough appearance.

[0134] 3.3. Summary of Evaluation Results As shown in Figure 6, in the evaluation of elongation, all examples received a rating of D or higher, which corresponds to "acceptable." In particular, Examples 1, 2, 4, and 6 received a rating of B or higher, indicating improved elasticity. In the evaluation of tensile strength, all examples received a rating of D or higher, which corresponds to "acceptable." In particular, Examples 2, 5, 6, and 8 received a rating of B or higher, indicating improved tensile strength. In the evaluation of surface condition under tension, all examples received a rating of B or higher, which corresponds to "acceptable," indicating improved appearance in the stretched state.

[0135] On the other hand, all of the comparative examples received an E rating, which corresponds to "unacceptable," for elongation and tensile strength, and a C rating, which also corresponds to "unacceptable," for surface condition under tension. This indicates that it is difficult to improve elongation, tensile strength, and surface condition under tension in the comparative examples. [Explanation of Symbols]

[0136] C... Raw material for fabric, CL1, CL2... Fabric for clothing, F... Fiber, L1... First layer, L2... Second layer, L3... Third layer, N1... Fabric, N3... Woven fabric, S2... Fiber defibration process, S3... Mixing process, S4... Lamination process, S5... Bonding process, S6... Molding process, T... Treatment agent, 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 the fibers obtained in the defibration step with an elastic treatment agent, A deposition step is to deposit the mixture in air onto a breathable and stretchable fabric, which will form the first layer, to generate a web, which will form the second layer. A method for manufacturing garment fabric, comprising a molding step of layering the aforementioned fabric and the aforementioned web and shaping them by heating and pressurizing them.

2. The method for manufacturing garment fabric according to claim 1, wherein the fabric has anisotropic elasticity.

3. The method for manufacturing garment fabric according to claim 1, wherein the mixture is deposited while stretching the fabric during the deposition step.

4. In the deposition process, the amount of the mixture deposited on the fabric is adjusted so that the basis weight of the second layer is 100 g / m². 2 More than 180g / m 2 The method for manufacturing clothing fabric according to claim 1, wherein the method is as follows:

5. The method for manufacturing garment fabric according to claim 1, wherein the mixing step involves mixing a liquid containing the treatment agent with the fibers.

6. The method for producing garment fabric according to claim 1, wherein the fabric comprises one or more of polyurethane and polymethylene terephthalate.

7. After the deposition step and before the molding step, the process includes a bonding step in which a third layer of fabric, which is less elastic than the fabric, is attached to the web. The method for manufacturing garment fabric according to claim 1, wherein in the molding step, the fabric, the web, and the woven fabric are layered and molded by heating and pressing.

8. The method for manufacturing garment fabric according to claim 1, wherein the type of treatment agent or the material of the fabric is changed depending on the material or weaving method of the fabric.

9. A first layer having breathability and elasticity, A garment fabric characterized by comprising a second layer, which is superimposed on the first layer and is formed by depositing an elastic treatment agent and fibers.

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