Thin and lightweight fabric made of double weave

Abstract

We provide a breathable, waterproof fabric that is thin and lightweight, yet offers excellent abrasion resistance and tear strength, especially on the surface of clothing. [Solution] A breathable waterproof fabric in which a double fabric is formed in which a front fabric made of warp threads W1 and weft threads F1 and a back fabric made of warp threads W2 and weft threads F2 are integrated at a predetermined bonding point, and the back fabric side is laminated with resin, wherein the unevenness height of the surface of the front fabric side of the fabric is 80 μm or more and 250 μm or less, and the back fabric has a grid-like protrusion.

Description

[Technical Field]

[0001] This invention relates to a thin, lightweight fabric made of double weave. More specifically, this invention relates to a breathable, waterproof fabric that is thin and lightweight, yet has excellent tear strength, and reduces surface irregularities to enhance abrasion resistance and aesthetics. [Background technology]

[0002] Synthetic fibers are widely used as functional materials for clothing, such as durable water-repellent materials and materials with moisture-wicking and quick-drying properties, for applications including sportswear and general clothing. In particular, demand for sportswear is increasing year by year with the spread of outdoor sports, and there is also a growing demand for lighter and thinner materials for tents, sleeping bags, canvas, and clothing. For this reason, nylon fibers, which generally have a higher breaking strength per denier than polyester, are widely used as the fiber material.

[0003] To meet the demand for lightweight and thin fabrics, for example, fabrics using low-density (i.e., fine) nylon fibers of the 40dtex class are used, and the fabric structure is made into ripstop taffeta to increase tear strength. Ripstop taffeta is a structure in which two or more warp and weft threads are arranged in parallel, separate from the base structure. However, as the density of the constituent threads decreases, the strength of the raw yarn itself decreases, and even if the fabric structure is made into ripstop taffeta to increase tear strength, it is not possible to obtain a fabric with satisfactory tear strength. In addition, if the weave density is reduced, thread slippage in the fabric itself becomes more likely, which does not lead to satisfactory weight reduction.

[0004] Thus, it is difficult to further reduce the weight of conventional lightweight fabrics while maintaining a tear strength that is not problematic in practical use. However, Patent Document 1 below proposes a fabric with a different fiber density arrangement that does not reduce tear strength and is lighter than conventional fabrics, by incorporating high-strength yarns with a specific fiber density into the warp and / or weft threads at regular intervals, in addition to the base yarn, when weaving lightweight fabrics.

[0005] However, while ripstop taffeta and fabrics with varying fiber counts offer improved tear strength, their uneven surface makes them less abrasion-resistant.

[0006] On the other hand, Patent Document 2 discloses a double-woven fabric in which the outer fabric and the inner fabric are integrated, but it lacks abrasion resistance due to the napping process, and also lacks downproof properties to prevent feathers or padding from leaking out.

[0007] Furthermore, Patent Document 3 below describes a heat flux of 84 kW / m 2 A heat-resistant and abrasion-resistant protective garment has been proposed, made from a base fabric that retains 10% or more of its tensile strength after being exposed to flames for 10 seconds. However, this garment is a double-woven fabric using spun yarn, has a high basis weight, and a stiff texture. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Patent No. 3980511 [Patent Document 2] Japanese Patent Application Publication No. 10-158951 [Patent Document 3] Japanese Patent Publication No. 2021-188143 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] In view of the level of prior art described above, the problem that the present invention aims to solve is to provide a breathable waterproof fabric that is thin and lightweight, yet has excellent abrasion resistance, aesthetics, and tear strength, especially on the surface of clothing. [Means for solving the problem]

[0010] As a result of intensive studies and repeated experiments to solve the above problems, the present inventors have unexpectedly found that by forming a thin and lightweight fabric as a double woven fabric, and forming the back woven fabric in a lattice shape while suppressing the unevenness on the surface of the face woven fabric, the abrasion resistance and aesthetic appearance of the surface can be enhanced while maintaining tear strength, leading to the completion of the present invention. That is, the present invention is as described below.

[0011] [1] A moisture-permeable waterproof fabric in which a face woven fabric composed of warp yarns W1 and weft yarns F1 and a back woven fabric composed of warp yarns W2 and weft yarns F2 are integrated at binding points at predetermined positions, and the back woven fabric side of the double woven fabric is laminated with a resin, wherein the unevenness height on the face woven fabric side surface of the fabric is 80 μm or more and 250 μm or less, and the back woven fabric has lattice-shaped protrusions. [2] The moisture-permeable waterproof fabric according to [1], wherein each of the warp yarns W1, weft yarns F1, warp yarns W2, and weft yarns F2 is a synthetic fiber multifilament. [3] The moisture-permeable waterproof fabric according to [1] or [2], wherein the synthetic fiber multifilament is a polyamide multifilament. [4] The moisture-permeable waterproof fabric according to any one of [1] to [3], wherein the cover factor (CF) of the face woven fabric is 1500 or more and 2000 or less, and the cover factor (CF) of the back woven fabric is 40 or more and 130 or less. [5] The moisture-permeable waterproof fabric according to any one of [1] to [4], wherein the fineness of each of the warp yarns W1 and weft yarns F1 is 8 dtex or more and 110 dtex or less, the fineness of each of the warp yarns W2 and weft yarns F2 is 22 dtex or more and 220 dtex or less, and the relationships of fineness of warp yarn W1 ≤ fineness of warp yarn W2 and fineness of weft yarn F1 ≤ fineness of weft yarn F2 are satisfied. [6] The basis weight is 30 g / m 2 or more and 100 g / m 2as follows, having a tear strength of 15 N or more in both warp and weft directions according to JIS L 1096-2010 8.17 Method D, an initial water repellency of Class 4 or higher based on JIS L 1092:2009 7.2 Water Repellency Test (Spray Test), a water repellency of Class 3 or higher after 20 washes based on JIS L 1092:2009 6.2.1 (Method C) (method using a household electric washing machine), a water pressure resistance of 0.2 MPa or more based on JIS L 1092 Method B (high water pressure method), a moisture permeability of 5000 or more according to JIS L 1099 Method A-1 (calcium chloride method), a moisture permeability of 30000 or more according to the same Method B-1 (potassium acetate method), and a wear resistance of the fabric surface of Class 4 or higher according to JIS L 1096 Method A-3 (crease method), the moisture-permeable waterproof fabric according to any one of the above [1] to [5]. [7] The moisture-permeable waterproof fabric according to any one of the above [1] to [6], wherein the resin is laminated by pasting a synthetic resin film or attaching a resin coating.

Effects of the Invention

[0012] The moisture-permeable waterproof fabric according to the present invention has a soft texture, abrasion resistance, lightweight property, and rain resistance. A thin and lightweight fabric is configured as a double woven fabric, and the back woven fabric is formed in a lattice shape while suppressing irregularities on the surface of the face woven fabric, thereby improving the surface abrasion resistance while maintaining the tear strength. Therefore, the moisture-permeable waterproof fabric according to the present invention can be suitably used as a functional material such as a durable water-repellent material or a water-absorbent quick-drying functional material in sports apparel applications such as downwear and down jackets, textile products such as tents, futons and sleeping bags, and material applications such as canvas.

Brief Description of the Drawings

[0013] [Figure 1] This is a design diagram (weave diagram) of the complete weave when the double woven fabrics of Examples 1 and 3 are viewed from the back woven fabric side. Small black squares (dark gray) indicate warp up. [Figure 2] This is a design diagram of the complete weave when the double woven fabrics of Examples 2 and 4 are viewed from the back woven fabric side. Small black squares (dark gray) indicate warp up. [Figure 3]Comparative Example 2 is a design drawing of the complete structure of a fabric with varying fiber density (single-ply fabric) according to Patent Document 3. [Figure 4] This is a design drawing of the complete structure of the ripstop fabric (single weave) of Comparative Example 3. [Figure 5] These are images showing the surface roughness of the front and back fabric sides of the double-woven fabric in Example 1, as well as measured surface images. [Figure 6] The image shows the surface roughness of the reverse side of the double-woven fabric from Example 1 after lamination, and is a measured surface image. [Figure 7] The image shows the surface roughness of the plain weave fabric of Comparative Example 1, and is a measured surface image. [Figure 8] The image shows the surface roughness of the surface of a fabric with varying fiber density arrangement (single-ply fabric) according to Patent Document 3 of Comparative Example 2, and is a measured surface image. [Figure 9] These are images showing the surface roughness of the ripstop structure (single-ply fabric) of Comparative Example 3, and measured surface images. [Modes for carrying out the invention]

[0014] Embodiments of the present invention will be described in detail below. One embodiment of the present invention is a breathable waterproof fabric in which a double fabric is formed in which a face fabric made of warp threads W1 and weft threads F1 and a back fabric made of warp threads W2 and weft threads F2 are integrated at a predetermined bonding point, and the back fabric side is laminated with resin, wherein the surface of the face fabric side of the fabric has a surface unevenness height of 80 μm or more and 250 μm or less, and the back fabric has a grid-like protrusion.

[0015] The yarns used for the warp threads W1 and weft threads F1 that make up the surface fabric are not particularly limited, but can be synthetic fiber multifilaments such as polyester (represented by polyethylene terephthalate and polytrimethylene terephthalate), polyamide, and polypropylene. Among these, synthetic fiber multifilaments such as polyester and polyamide are preferred from the viewpoint of strength and abrasion resistance as clothing. The yarns used for the warp threads W2 and weft threads F2 that make up the reverse fabric are not particularly limited, but can be synthetic fiber multifilaments such as polyester represented by polyethylene terephthalate and polytrimethylene terephthalate, polyamide, polypropylene, high-strength fiber polyarylate, ultra-high molecular weight polyethylene, and liquid crystal polyester. Among these, from the viewpoint of strength as a garment, synthetic fiber multifilaments such as polyamide, high-strength fiber polyarylate, ultra-high molecular weight polyethylene, and liquid crystal polyester are preferred. It is preferable that all the yarns used for the warp threads W1 and weft threads F1, and for the warp threads W2 and weft threads F2, be synthetic fiber multifilaments, and it is particularly preferable that all of them be polyamide multifilaments.

[0016] Warp threads W1 and weft threads F1, and warp threads W2 and weft threads F2 may be supplemented with one or more of the following, as needed: matting agents, micropore forming agents, cationic dyeing agents, color inhibitors, heat stabilizers, flame retardants, fluorescent whitening agents, colorants, antistatic agents, hygroscopic agents, antibacterial agents, inorganic fine particles, etc.

[0017] For the warp threads W1 and weft threads F1, it is preferable to use untwisted or loosely twisted long fibers of 800 T / m or less, more preferably 500 T / m or less, in order to reduce the gaps formed between the warp threads W1 and weft threads F1 and to improve surface abrasion resistance. Furthermore, the warp threads W1 and weft threads F1 may also be subjected to air processing such as covering, false twist crimping, Taslan processing, or interlacing.

[0018] From the viewpoint of texture and lightness, the warp threads W1 and weft threads F1 preferably have a total fineness of 8 dtex or more and 78 dtex or less, more preferably 17 dtex to 78 dtex, and more preferably 20 dtex to 50 dtex, and the single fiber fineness is preferably 0.5 or more and less than 5 dtex, and more preferably 1 dtex to 3 dtex. If the total fiber density is less than 8 dtex, the fabric will be lightweight but will have poor downproof properties as a woven fabric. On the other hand, if the total fiber density exceeds 78 dtex, the fabric will lose its lightweight feel.

[0019] The warp threads W2 and weft threads F2 have a total fineness of 22 dtex to 220 dtex, more preferably 33 dtex to 110 dtex, and even more preferably 33 dtex to 78 dtex, from the viewpoint of texture, lightness, and tear strength, and the single fiber fineness is preferably 0.5 to less than 5 dtex, and more preferably 1 dtex to 3 dtex. If the total fineness is less than 8 dtex, the tear strength of the fabric is low, on the other hand, if the total fineness exceeds 78 dtex, the difference in fineness between the surface and the weft becomes large, making weaving difficult.

[0020] It is preferable that the fineness of both the warp thread W1 and the weft thread F1 is 8 dtex or more and 78 dtex or less, the fineness of both the warp thread W2 and the weft thread F2 is 22 dtex or more and 220 dtex or less, and that the relationship between the fineness of warp thread W1 ≤ fineness of warp thread W2 and the fineness of weft thread F1 ≤ fineness of weft thread F2 is satisfied. W1 and F1 need to have a fine fineness and a constant cover factor in order to achieve lightness and surface smoothness, and W2 and F2 need to be high fineness and high toughness yarns in order to improve tear strength. The fineness of W1 may equal the fineness of W2, or the fineness of F1 may equal the fineness of F2. However, if the fineness of W1 equals the fineness of W2 and the fineness of F1 equals the fineness of F2, the strength is superior, but the physical properties of the fabric tend to be slightly reduced.

[0021] Although woven fabrics cannot be perfectly flat due to the intersection of warp and weft threads, in the breathable waterproof fabric of this embodiment, the unevenness height of the surface of the outer woven fabric is 80 μm to 250 μm, and the back woven fabric has a grid-like pattern of protrusions. Furthermore, in the breathable waterproof fabric of this embodiment, the unevenness of the back woven fabric side of the double woven fabric, which is removed by peeling off the laminate coating, can be measured. Here, on the surface of the front fabric, at the connection point, the warp threads W2 and weft threads F2 that make up the back fabric are partially exposed (see Figures 1 and 2), and the height of the unevenness is equivalent to the fiber diameter of the warp threads W1 and weft threads F1. Furthermore, on the surface of the reverse fabric, the height of the unevenness is calculated by adding the fiber diameter equivalent to the warp threads W2 and weft threads F2 that make up the reverse fabric to the difference in unevenness of the front fabric.

[0022] From the viewpoints of the cover factor (CF) and tear strength of the double woven fabric, the protrusion interval, which is the length of one side of the grid-like convex portions of the back woven fabric, is preferably 1 mm or more and 10 mm or less in the warp direction and / or the weft direction, more preferably 1.2 mm or more and 5.0 mm or less. It is preferable that this interval in either the warp or weft direction satisfies the above range, and it is more preferable that both the warp direction and the weft direction fall within the above range. This interval can be adjusted by selecting the weave structure, the number ratio of W1 to W2, and / or the number ratio of F1 to F2.

[0023] The basis weight of the double woven fabric is preferably 30 g / m 2 or more and 100 g / m 2 or less, more preferably 35 or more and 70 g / m 2 or less. If the basis weight is less than 30 g / m 2 , the down-proof property deteriorates. On the other hand, if it exceeds 100 g / m 2 , the hand feel becomes stiff, which is not preferable for clothing. In the case of a moisture-permeable and waterproof fabric in which the back woven fabric side of the double woven fabric is laminated and coated, the basis weight of the fabric is preferably 50 g / m 2 or more and 120 g / m 2 or less, more preferably 55 or more and 90 g / m 2 or less.

[0024] From the viewpoints of lightweight properties, tear strength, air permeability and the like, it is preferable that the cover factor (CF) of the face woven fabric is 1500 or more and 2000 or less, and the cover factor (CF) of the back woven fabric is 40 or more and 130 or less. Here, the cover factor (CF) is determined by the following formula for each of the face woven fabric (warp yarn W1, weft yarn F1) and the back woven fabric (warp yarn W1, F2) constituting the double woven fabric. CF=N W ×(D W ) 1 / 2 +N F ×(D F ) 1 / 2 {In the formula, N W is the warp weaving density (yarns / inch (2.54 cm)), and N FThis is the weft density (threads / inch (2.54cm)), and D W This is the total fineness of the warp threads (dtex), and D F This is the total fineness (dtex) of the weft threads. If the cover factor (CF) of the outer fabric is less than 1500, the gaps formed between the warp and weft threads become large, making it impossible to maintain downproof properties, etc. On the other hand, if it exceeds 2000, the fabric becomes heavy, the texture deteriorates, and productivity also decreases. On the other hand, the cover factor (CF) of the backing fabric having a grid-like protrusion (see Figures 1 and 2) is preferably 40 to 130, and more preferably 50 to 90. If the cover factor of the backing fabric is less than 40, it becomes difficult to improve the tear strength. On the other hand, if it exceeds 130, the fabric becomes heavy, the texture deteriorates, and productivity also decreases.

[0025] The structure of the outer fabric of the double-woven fabric is not particularly limited and can be any known weave structure such as plain weave, twill weave, or satin weave, but among these, plain weave is most preferred from the viewpoint of obtaining surface smoothness and excellent abrasion resistance.

[0026] The preferred structure of the back fabric of the double-woven fabric is one in which, from the viewpoint of improving the abrasion resistance of the surface of the front fabric, the portion of the warp threads W2 and weft threads F2 exposed on the surface is small, making it difficult for irregularities to occur, and from the viewpoint of improving tear strength, the structure in which the warp threads W2 and weft threads F2 are largely exposed on the surface of the back fabric is preferred. Specifically, a preferred structure is a double-woven fabric as illustrated in Figures 1 and 2.

[0027] The weaving method for the double-layered fabric can be a conventional method using a conventional loom (for example, a conventional water jet loom, air jet loom, rapier loom, etc.), but from the viewpoint of using two or more types of yarn, it is preferable to use a double-beam loom.

[0028] The breathable waterproof fabric of this embodiment is characterized in that the back fabric side of the double-woven fabric is laminated with resin. Resin lamination here may be in the form of attaching a resin film or attaching a resin coating. Specifically, lamination of the back fabric side with resin means attaching (laminating) or coating (coating) a porous or non-porous resin film to the surface of the back side. The material of the resin film is not particularly limited; any resin capable of exhibiting moisture permeability and waterproofing performance, such as polyurethane films, polycarbonate films, or polypropylene / polyethylene films, is acceptable, although polyurethane films are preferred from the viewpoint of texture. Porous and non-porous films can be used as the film. The lamination method is also not particularly limited; the above films can be attached (laminated) by gravure bonding or screen bonding. The resin coating is not particularly limited and can be any resin capable of exhibiting moisture permeability and waterproofing performance, such as acrylic resin, polyurethane resin, or polycarbonate resin. Polyurethane resin is preferred from the viewpoint of texture and moisture permeability. The above resin can be applied to the surface (coated) by spray coating, dip coating, floating knife coating, etc.

[0029] It is preferable that the outer surface of the double-woven fabric (the surface when used as clothing) is treated with a water-repellent finish. The type of water-repellent agent is not particularly limited. Examples include fluorine-based compounds, hydrocarbon-based compounds, and silicone-based compounds. If necessary, it is preferable to mix an antistatic agent, melamine resin, and catalyst to make a processing agent with a water-repellent concentration of about 3 to 15% by weight, and to treat the surface using this processing agent with a pickup rate of about 50 to 90%. Examples of methods for treating the surface with the processing agent include the pad method and the spray method. Among these, the pad method is preferred for penetrating the processing agent into the interior of the fabric. The pickup rate is the weight ratio (%) of the processing agent to the weight of the fabric (before application of the processing agent).

[0030] Furthermore, applying calendering to the double-woven fabric in at least one of the pre- and post-water-repellent processing steps is preferable because it provides excellent rain resistance and down leakage prevention. In this case, the calendering conditions are preferably a temperature of 130°C or higher (more preferably 140 to 195°C) and a linear pressure within the range of 200 to 20000 N / cm (more preferably 200 to 1000 N / cm).

[0031] Furthermore, conventional dyeing, alkali weight reduction, and napping processes may be performed in at least one of the pre- and post-water-repellent processes. In addition, ultraviolet shielding agents, antibacterial agents, deodorizers, insect repellents, phosphorescent agents, retroreflective agents, negative ion generators, etc., may be added.

[0032] The tear strength of the double-woven fabric in either the warp or weft direction, preferably both, is preferably 10 N or more. Here, the tear strength shall be measured according to JIS L 1096-2010 8.17 Method D.

[0033] The initial water repellency of the double-woven fabric is preferably grade 4 or higher, and more preferably grade 4 to 5 or higher. Here, the water repellency shall be measured by JIS L 1092:2009 7.2 water repellency test (spray test). Furthermore, it is preferable that the water repellency of the double-woven fabric is grade 3 or higher after being washed 20 times according to JIS L 1092:2009 6.2.1 (Method C) (Method using a household electric washing machine).

[0034] The abrasion resistance of the fabric surface of the breathable waterproof fabric of this embodiment, according to the JIS L 1096 A-3 method (fold method), is preferably grade 3 or higher. [Examples]

[0035] The present invention will be described in detail below with reference to examples and comparative examples, but the present invention is not limited thereto. First, the measurement methods for each measurement item used in the examples and comparative examples are described below.

[0036] (1) Total fineness, number of filaments (single yarns) The total fineness of the raw yarn and the constituent yarns extracted from the fabric was measured according to JIS L 1013:2010 8.3.1 (Method A) (Fineness). The number of filaments in the raw yarn and the constituent yarn extracted from the fabric was measured in accordance with JIS L 1013:2010 8.4.

[0037] (2) Weaving density The weave density of the fabric at the time of finishing was measured according to JIS L 1096:2010 8.6.1 (Method A). The fabric sample was placed on a flat surface, and after removing any unnatural wrinkles or tension, the number of warp and weft threads per 0.5 cm section was counted at five different locations. The average value for each was calculated and converted to the number of threads per inch (2.54 cm).

[0038] (3) Coverage Factor (CF) The cover factor (CF) was calculated for each of the double-layered fabrics—the front fabric (warp W1, weft F1) and the back fabric (warp W1, F2)—as well as for single-layered fabrics, using the following formula. CF=N W ×(D W ) 1 / 2 +N F ×(D F ) 1 / 2 {In formula, N W This is the warp weave density (threads / inch (2.54cm)), N F This is the weft density (threads / inch (2.54cm)), and D W This is the total fineness of the warp threads (dtex), and D F This is the total fineness (dtex) of the weft threads.

[0039] (4) Water pressure resistance Measurements were taken according to JIS L 1092 Method B (high water pressure method). However, because the outer and inner fabrics are knitted, excessive swelling often occurs during measurement, hindering the measurement process. To prevent this, a 210-thread count plain weave taffeta fabric (warp density 120 threads / inch, weft density 90 threads / inch) using 78dtex / 24f nylon 6 multifilament yarn for both warp and weft was layered on top of the laminated fabric for measurement. The unit is [MPa].

[0040] (5) Breathability Measurements were taken according to JIS L 1099 A-1 method (calcium chloride method) and B-1 method (potassium acetate method).

[0041] (6) Height of unevenness (μm), and distance between protrusions (mm) The surface surface roughness height (μm) was measured using a Keyence "One-Shot 3D Microscope VR-3200" under the following measurement conditions. • Cotton roughness (cross-sectional roughness) • Lens: Low magnification lens, Magnification: 12x, Fine mode • Surface shape correction: 5 times stronger undulation removal ·Area area: 4.35×10 8 μm 2 Measure 10mm horizontally. In this measurement, the difference in height between the highest and lowest points of the repeated bumps on the fabric was defined as the bump height, and the distance between adjacent grid-like bumps was defined as the bump spacing. Both measurements were taken at different locations for n=5 measurements, and the average value was calculated.

[0042] (7) Water repellency (grade) Water repellency was measured initially, and after 20 washes according to JIS L 1092:2009 6.2.1 (Method C) (Method using a household electric washing machine), and then according to the 7.2 water repellency test (spray test).

[0043] (8) Tear strength (N) The tear strength (N) of the fabric was measured according to JIS L 1096-2010 8.17 Method D.

[0044] (9) Abrasion resistance (grade) The abrasion resistance of the fabric was measured according to JIS L 1096 A-3 method (fold method).

[0045] (10) Weight (g / m 2 ) The mass per unit area of ​​the fabric was measured according to JIS L 1096-2010 8.3 Method A. If a test specimen of the required size could not be obtained, the sample size was changed as appropriate and measured, and the basis weight (g / m²) was calculated from the obtained value. 2 ) was calculated.

[0046] [Example 1] Using nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the warp thread W1 of the face fabric, nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the weft thread F1 of the face fabric, nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the warp thread W2 of the back fabric, and nylon 66 multifilament DTY yarn with a total fineness of 78 dtex and 34 filaments as the weft thread F2 of the back fabric, a raw fabric with the complete structure shown in Figure 1 when viewed from the back fabric side was produced using an air jet loom. This raw fabric underwent scouring, intermediate setting, dyeing, non-fluorine water-repellent treatment, and finishing setting to produce a water-repellent dyed fabric with a warp density of 180 threads / inch (2.54 cm) and a weft density of 131 threads / inch. A polyurethane porous membrane film (thickness 20 μm) was prepared and bonded to the reverse woven surface of the fabric using a polyurethane-based adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0047] [Example 2] Except for changing the structure to the complete structure shown in Figure 2, a water-repellent dyed fabric with a warp density of 180 threads / inch (2.54 cm) and a weft density of 130 threads / inch was obtained in the same manner as in Example 1. A polyurethane porous film (thickness 20 μm) was prepared and bonded to the surface of the woven fabric side of the material using a polyurethane adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0048] [Example 3] Using nylon 66 multifilament DTY yarn with a total fineness of 17 dtex and 5 filaments as the warp thread W1 of the face fabric, nylon 66 multifilament DTY yarn with a total fineness of 17 dtex and 5 filaments as the weft thread F1 of the face fabric, nylon 66 multifilament DTY yarn with a total fineness of 17 dtex and 5 filaments as the warp thread W2 of the back fabric, nylon 66 multifilament DTY yarn with a total fineness of 56 dtex and 24 filaments as the weft thread F2 of the back fabric, a raw fabric with the complete structure shown in Figure 3 when viewed from the back fabric side was produced using an air jet loom. This raw fabric underwent scouring, intermediate setting, dyeing, non-fluorine water-repellent treatment, and finishing setting to produce a water-repellent dyed fabric with a warp density of 291 threads / inch (2.54 cm) and a weft density of 210 threads / inch. A polyurethane porous membrane film (thickness 20 μm) was prepared and bonded to the reverse woven surface of the fabric using a polyurethane-based adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0049] [Example 4] Except for changing the structure to the complete structure shown in Figure 2, the same procedure as in Example 3 was followed to obtain a water-repellent dyed fabric with a warp density of 290 threads / inch (2.54 cm) and a weft density of 212 threads / inch. A polyurethane porous membrane film (thickness 20 μm) was prepared and bonded to the reverse woven surface of the fabric using a polyurethane-based adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0050] [Comparative Example 1] Using nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the warp threads, and nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the weft threads, a plain weave fabric was prepared using an air jet loom. This raw fabric underwent scouring, intermediate setting, dyeing, non-fluorine water-repellent treatment, and finishing setting to produce a water-repellent dyed fabric with a warp density of 168 threads / inch (2.54 cm) and a weft density of 118 threads / inch. A porous polyurethane film (thickness 20 μm) was prepared and bonded to the fabric using a polyurethane adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0051] [Comparative Example 2] (Equivalent to the invention described in Patent Document 3) Using a water jet loom, raw fabric of a fully structured, heterogeneous denier woven fabric (single weave) was produced, using nylon 66 multifilament DTY yarn with a total fineness of 8 dtex and 5 filaments, and nylon 66 multifilament DTY yarn with a total fineness of 78 dtex and 34 filaments, arranged in a warp:25:1 and weft:21:1, as shown in Figure 3. This raw fabric underwent scouring, intermediate setting, dyeing, non-fluorine water-repellent treatment, and finishing setting to produce a water-repellent dyed fabric with a warp density of 290 threads / inch (2.54 cm) and a weft density of 230 threads / inch. A porous polyurethane film (thickness 20 μm) was prepared and bonded to the fabric using a polyurethane adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0052] [Comparative Example 3] Using nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the warp threads, and nylon 66 multifilament DTY yarn with a total fineness of 44 dtex and 34 filaments as the weft threads, a ripstop fabric as shown in Figure 4 was prepared using an air jet chamber. This raw fabric underwent scouring, intermediate setting, dyeing, non-fluorine water-repellent treatment, and finishing setting to produce a water-repellent dyed fabric with a warp density of 156 threads / inch (2.54 cm) and a weft density of 135 threads / inch. A porous polyurethane film (thickness 20 μm) was prepared and bonded to the fabric using a polyurethane adhesive via gravure bonding. The physical properties of the waterproof and breathable fabric after processing are shown in Table 1 below.

[0053] The evaluation results for Examples 1-4 and Comparative Examples 1-3 are shown in Table 1 below. [Table 1] [Industrial applicability]

[0054] The breathable waterproof fabric according to the present invention has a soft texture, abrasion resistance, lightness, and rain resistance, while being constructed as a thin, lightweight double-woven fabric. By suppressing surface irregularities of the outer fabric and forming the inner fabric in a grid pattern, tear strength is maintained while surface abrasion resistance is enhanced. Therefore, the breathable waterproof fabric according to the present invention can be suitably used as a durable water-repellent material or a functional material with water absorption and quick-drying properties in sportswear such as down wear and down jackets, textile products such as tents, futons, and sleeping bags, and materials such as canvas.

Claims

1. A breathable waterproof fabric in which a double fabric is formed in which a front fabric made of warp threads W1 and weft threads F1 and a back fabric made of warp threads W2 and weft threads F2 are integrated at a predetermined bonding point, and the back fabric side is laminated with resin, wherein the surface of the front fabric side of the fabric has a surface unevenness height of 80 μm or more and 250 μm or less, and the back fabric has a grid-like protrusion.

2. The breathable waterproof fabric according to claim 1, wherein the warp thread W1, weft thread F1, warp thread W2, and weft thread F2 are all synthetic fiber multifilaments.

3. The breathable waterproof fabric according to claim 1 or 2, wherein the synthetic fiber multifilament is a polyamide multifilament.

4. The breathable waterproof fabric according to claim 1 or 2, wherein the cover factor (CF) of the outer fabric is 1500 or more and 2000 or less, and the cover factor (CF) of the inner fabric is 40 or more and 130 or less.

5. The breathable waterproof fabric according to claim 1 or 2, wherein the fineness of the warp thread W1 and the weft thread F1 is both 8 dtex or more and 110 dtex or less, the fineness of the warp thread W2 and the weft thread F2 is both 22 dtex or more and 220 dtex or less, and the relationship between the fineness of warp thread W1 ≤ fineness of warp thread W2 and the fineness of weft thread F1 ≤ fineness of weft thread F2 is satisfied.

6. Weight: 30g / m ２ More than 100g / m ２ The following conditions must be met: the tear strength according to JIS L 1096-2010 8.17 Method D is 15N or higher in both warp and weft directions; the initial water repellency according to JIS L 1092:2009 7.2 water repellency test (spray test) is grade 4 or higher; and after 20 washes according to JIS L 1092:2009 6.2.1 (Method C) (Method using a household electric washing machine), the water repellency is grade 3 or higher; the water pressure resistance according to JIS L 1092 Method B (High water pressure method) is 0.2 MPa or higher; the moisture permeability according to JIS L 1099 Method A-1 (Calcium chloride method) is 5000 or higher; the moisture permeability according to Method B-1 (Potassium acetate method) is 30000 or higher; and JIS L 1096 A breathable waterproof fabric according to claim 1 or 2, wherein the abrasion resistance of the fabric surface according to the A-3 method (folding method) is grade 4 or higher.

7. The breathable waterproof fabric according to claim 1 or 2, wherein the resin is laminated by attaching a synthetic resin film or by having a resin coating attached.

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