Fabric structure

Abstract

The present invention is a woven structure characterized by comprising a first layer having a first needle punch density, a second layer located below the first layer and having a second needle punch density lower than the first needle punch density, a third layer located below the second layer, a stitching structure in which the first layer, second layer, and third layer are stitched together, and an air vent groove structure in which the first layer and / or the third layer have convex portions facing outward and concave portions facing inward in a cross section.

Description

[Technical Field]

[0001] The present invention relates to a fabric structure, and more particularly to a fabric having an air channel structure. [Background technology]

[0002] With the development of synthetic materials and manufacturing technology, insulating materials with functions of heat insulation, sound insulation, filtration, etc. have been widely applied in many products. For example, insulating materials are applied to the following products and / or fields according to their properties: cold weather gear, industrial / building heat insulation, sound insulation, etc., but are not limited to these.

[0003] The conventional method for producing fabrics used in commercially available separators involves first spraying a chemical resin onto a fiber web or mixed hot-melt cotton, then placing the fabric in a large, high-temperature dryer to dry and shape the resin. This production method requires the use of a large amount of chemical resin and consumes a large amount of fuel to provide high-temperature drying using a crucible or burner. In addition, the above production method generates large amounts of carbon dioxide, waste gases, and wastewater pollution, and such high-temperature, polluted environments pose health concerns for producers. Summary of the Invention

[0004] In view of the problems inherent in conventional production techniques, the present inventors have proposed a fabric with a ventilation groove structure and a method for manufacturing the same. This method does not require the use of chemical resins or large, high-temperature dryers, and eliminates the drying process required for resins and hot-melt cotton. It also has the advantage of being compatible with various long-fiber nonwovens, short fibers, or long filaments / film materials. Therefore, the fabric of the present invention has multifunctional and breathable properties, and achieves environmental protection goals of no chemical resins, energy conservation, and zero carbon emissions.

[0005] The present invention relates to a woven structure, comprising: a first layer comprising first fibers and having a first needlepunching density; a second layer located below the first layer, comprising second fibers and having a second needlepunching density less than the first needlepunching density; a third layer located below the second layer for enhancing isolation of the woven fabric; a stitching structure for stitching and fixing the first layer, the second layer, and the third layer together; and an air vent structure in which, in cross section, the first layer has a first set of outward convex portions and a first set of inward concave portions, and the third layer has a second set of outward convex portions and a second set of inward concave portions.

[0006] The first set of outwardly directed convex portions have the same first width, the first set of inwardly directed concave portions have the same second width, the second set of outwardly directed convex portions have the same third width, and the second set of inwardly directed concave portions have the same fourth width.

[0007] The first width is substantially equal to the third width, and the second width is substantially equal to the fourth width.

[0008] The first width is not equal to the third width, and the second width is not equal to the fourth width.

[0009] The first set of outwardly extending convex portions have different widths, and the second set of outwardly extending convex portions have different widths.

[0010] The first fibers have a thickness of 0.5 dtex to 15 dtex, and the second fibers have a thickness of 0.5 dtex to 15 dtex.

[0011] The second layer and the first layer are bonded together at the second needlepunch density.

[0012] Furthermore, In a cross section, the first layer or the third layer has an air vent groove structure having a first set of outwardly directed convex portions and a first set of inwardly directed concave portions.

[0013] The first set of outwardly directed convex portions have the same first width, and the first set of inwardly directed concave portions have the same second width.

[0014] The first set of outwardly directed ridges have different widths.

[0015] the first layer having the first set of outwardly directed peaks and the first set of inwardly directed valleys, a fourth layer underlying the third layer, the fourth layer comprising the first fibers and having a first needlepunch density; a fifth layer below the fourth layer, the fifth layer comprising second fibers and having a second needlepunch density; a sixth layer located below the fifth layer for enhancing isolation of the fabric; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; In a cross section of the air channel structure, the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions.

[0016] the first layer having the first set of outwardly directed peaks and the first set of inwardly directed valleys, and the woven structure further comprising: a fourth layer located below the third layer for enhancing isolation of the fabric; a fifth layer underlying the fourth layer, the fifth layer comprising second fibers and having a second needlepunch density; a sixth layer underlying the fifth layer, the sixth layer comprising the first fibers and having the first needlepunch density; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; In a cross section of the air channel structure, the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions.

[0017] the third layer having the first set of outwardly directed convex portions and the first set of inwardly directed concave portions; and a fourth layer positioned above the first layer, the fourth layer comprising the first fibers and having the first needlepunch density; a fifth layer positioned above the fourth layer, the fifth layer comprising the second fibers and having the second needlepunch density; a sixth layer positioned above the fifth layer to enhance isolation of the fabric; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; In a cross section of the air channel structure, the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions.

[0018] The first set of outwardly directed convex portions have the same first width, the first set of inwardly directed concave portions have the same second width, the second set of outwardly directed convex portions have the same third width, and the second set of inwardly directed concave portions have the same fourth width.

[0019] The first width is substantially equal to the third width, and the second width is substantially equal to the fourth width.

[0020] The first fibers have a thickness of 0.5 dtex to 15 dtex, and the second fibers have a thickness of 0.5 dtex to 15 dtex.

[0021] The second layer and the first layer are bonded together at the second needlepunch density.

[0022] The second layer and the first layer are bonded together at the second needlepunch density, and the fifth layer and the fourth layer are bonded together at the second needlepunch density.

[0023] The second layer and the first layer are bonded together at the second needlepunch density, and the sixth layer and the fifth layer are bonded together at the second needlepunch density.

[0024] These and other features of the disclosed embodiments are described in detail below with reference to the associated figures. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 1 is a flow diagram showing a method for manufacturing a breathable fabric. [Figure 2] 1 is a schematic diagram of a cross section of a fabric. [Figure 3] 1 is a schematic diagram of a cross section of a woven fabric having a stitched structure. [Figure 4] 1 is a schematic diagram of a cross section of a fabric having an air channel structure. [Figure 5(a)-(d)] 1 is a schematic cross-sectional view of the upper and lower needle plate pin headers of a forward / reverse needle device. [Figure 6(a)-(d)] 1 is a schematic diagram of a cross section of a single layer fabric with different groove arrangements. [Figure 7(a)-(b)] 1 is a schematic diagram of a cross section of a different two-layer fabric having a groove structure. [Figure 8] FIG. 1 is a top view of a woven fabric having stitching and groove structures. DETAILED DESCRIPTION OF THE INVENTION

[0026] In the following description, some specific details are provided to provide a thorough understanding of the embodiments. The embodiments described herein may be practiced without some or all of these specific details. In other circumstances, conventional processing operations will not be described in detail so as not to unnecessarily obscure the disclosed embodiments. While the embodiments disclosed herein are described using specific examples, it is understood that they are not limited to these disclosed examples.

[0027] FIG. 1 shows a method 100 for producing a breathable fabric of the present invention, which will be explained below with reference to FIGS.

[0028] 2 shows a schematic diagram of a fabric 200 according to one embodiment of the present invention. The fabric 200 includes a first layer 202, a second layer 204, and a third layer 206.

[0029] First, in step 102 of the manufacturing method 100 of FIG. 1, a first fiber having a predetermined fiber specification and weight is formed into a fiber web, and then needle-punched with a needle punch machine at, for example, 50 to 300 punches / cm. 2The high-density needle punching has the effect of increasing the entanglement of the fibers, thereby producing a thin, flat, and structurally strong first layer 202 that is tightly and firmly entangled by entangling the originally loose and weak fiber web.

[0030] In one embodiment, the first fiber material may be PP / PET staple fiber, and the fiber thickness may be 0.5 dtex to 15 dtex (decitex) and the length may be 31 to 100 mm. The weight of the fiber web may be 40 to 160 gsm (Gram per Square Meter). In a more preferred embodiment, the thickness of the PP / PET staple fiber may be 0.5 dtex to 7 dtex.

[0031] In step 104 of the manufacturing method 100, a fiber web is formed from a second fiber having a predetermined fiber specification and weight, and then a reverse single-sided low-density needle punch is performed using a counter needle punching machine (e.g., 3 to 50 punches / cm). 2 In this case, the needle punching density is lower or zero, which reduces the inter-fiber entanglement effect. Therefore, a bulky, elastic, and supportive second layer 204 can be produced, and the effect of increased air content can be achieved. In another embodiment, the second fibers are formed into a fibrous web, which is then laminated with the first layer 202, and then low-density needle punching is performed using a counter-needle punching machine. At this time, the second layer and the first layer are bonded together at a low needle punching density.

[0032] In one embodiment, the second fiber material may be PP / PET short fiber / long fiber, and the fiber thickness may be 0.5 dtex to 15 dtex, and the length may be 31 mm to infinite. The weight of the fiber net (web) may be 10 to 300 gsm. In one more preferred embodiment, the fiber thickness is 3 dtex to 15 dtex.

[0033] The first layer has a high needle punch density, providing structural strength and insulation, while the second layer has a low needle punch density, maintaining the bulk, flexibility, and support of the fibers while increasing air volume and thermal insulation. Thus, combining the first and second layers provides the advantage of a multi-functional combination.

[0034] In addition, the first and / or second layers can be mixed with other different fiber materials to achieve more multi-functional combinations, such as hollow fibers, elastic fibers, regenerated fibers, bicomponent fibers, polylactic acid fibers, and natural fibers.

[0035] In step 106 of manufacturing method 100, first layer 202, second layer 204, and third layer 206 are sewn together to form woven fabric 300 with a stitched structure 302 (as shown in FIG. 3). The third layer enhances the isolation (e.g., isolation of air, moisture, etc.) and heat retention properties of the present invention and prevents fiber loosening. The spaces secured in each layer in this manner allow each fiber layer to move freely within the space. In dynamic conditions, each fiber can freely flutter due to vibration, increasing airflow and heat dissipation. In static conditions, the fiber layers are inactive and each fiber layer has a different natural rising or contracting shape, allowing the fiber layers to naturally expand and become more bulky, increasing air volume and heat retention. This increases the flexibility and improves the rigidity of the woven fabric. In contrast, conventional insulating materials fix fibers into a sheet structure overall, which does not achieve the beneficial effects of the present invention.

[0036] In one embodiment, the third layer may be made of a PP meltblown nonwoven fabric and may have a weight of 10 to 100 gsm. In other embodiments, the third layer may be made of a PP / PET spunbond nonwoven fabric, a waterproof film, a metallized film, or the like. In one embodiment, the seam structure is formed by ultrasonic continuous dot welding and has a double diamond lattice floral pattern. In other embodiments, the seam structure may be fixed by a hot bond roll or high frequency stitching. In other embodiments, the seam structure may have a dotted geometric pattern or an even number pattern. In addition, when fixing by stitching, a fourth layer may be optionally added near the first layer to provide additional protection for the first layer. The fourth layer may be made of a nonwoven fabric, such as a long filament nonwoven fabric, and may have a weight of 9 to 20 gsm.

[0037] Returning to FIG. 1 , in step 108, the sewn fabric (e.g., fabric 300 in FIG. 3 ) is passed through a needle-punch device to create an air vent structure. In one example, the sewn fabric is passed through a single-sided needle punch, with needles positioned on the upper or lower needle plate at a desired pitch to create a single-sided air vent structure 400 (shown in FIG. 4 ) in the cross section of the fabric. The air vent structure 400 includes outwardly facing convex portions and inwardly facing concave portions 404. The needle-punching intermittently entangles and fixes the fibers of the first, second, and third layers, forming inwardly facing concave portions toward the interior of the fabric, while numerous needle-punched voids are formed in the inwardly facing concave portions. Therefore, the inwardly facing concave portions can increase the breathability of the fabric. The inwardly facing concave portions 404 are formed by the needle-punching, where the fibers of the first layer penetrate into the second and third layers, creating edges 406 on the outside of the first and third layers. The outward convex portions that are not needle-punched maintain a certain fiber bulk thickness to achieve a thermal insulation effect. The depth of the grooves and breathability can be adjusted by controlling the needle-punching density. The higher the needle-punching density, the thinner and firmer the fiber layer becomes, and the larger the needle holes, the better the breathability. In the embodiment of FIG. 4, the first layer 202 has outward convex portions and inward concave portions, while the third layer is held substantially flat. In another embodiment, the third layer has outward convex portions and inward concave portions, while the first layer is held substantially flat. The total weight of the resulting fabric is approximately 60-400 gsm, and the thickness is approximately 3-30 mm.

[0038] In another example, a single layer of sewn fabric is passed through a forward / backward needle punch machine, with needles arranged at a desired pitch on the upper or lower needle plate to create a double-sided ventilation groove structure across the cross section of the fabric. Unlike conventional needle plate arrangements, the needle hole sizes and positions of the stress guide plate and the peel guide plate of this needle punch machine are different. In particular, the upper and lower needle plates and guide plates must be designed with a high density to create the ventilation grooves. The double-sided groove structure design improves the structural strength, stretchability, and flexibility of the fabric, and also improves air circulation and reflective effects within the groove structure, thereby overcoming the drawbacks of traditional thick, heavy cotton layers, which are thick, stiff, and lacking flexibility.

[0039] When using a forward / reverse needle punching device, depending on the different product requirements, the needles on the upper and lower needle plates can be adjusted to the same width W and pitch D (as shown in FIG. 5(a)) to form inward recesses of the same width on both sides of the fabric (as shown in the ventilation groove structure 600 in FIG. 6(a)). This allows for approximately the same ventilation effect on both sides of the fabric. Alternatively, the needles on the upper and lower needle plates can be adjusted to different widths and pitches (as shown in FIG. 5(b) or 5(c)) to form inward recesses of different widths on both sides of the fabric (as shown in the ventilation groove structure 610 in FIG. 6(b) or the ventilation groove structure 620 in FIG. 6(c)). In this way, the ventilation effect on both sides of the fabric can be different, improving heat retention on one side and ventilation and heat dissipation on the other side. Alternatively, the needles on the upper and lower needle plates can be adjusted to the same width but different pitches (as shown in FIG. 5(d)) to form outward protrusions of different widths (as shown in the ventilation groove structure 630 in FIG. 6(d)). Depending on the breathability requirements, the groove structure can be designed to different widths, with some areas having more inward recesses for better breathability, and other areas having fewer inward recesses for better thermal insulation.

[0040] The depth of the inward recesses varies depending on the needle punch density, fiber thickness, and material. For example, in a ventilation groove structure, the width of the inward recesses is 2.5 to 100 mm, the width of the outward protrusions is 5 to 300 mm, and the needle punch density is 10 to 200 punches / cm. 2 Any of the above parameters can be adjusted as needed.

[0041] In one example, two sewn layers of fabric (e.g., fabric 300) are stacked one on top of the other and passed through a forward / reverse needle punch machine. Similarly, by arranging the needles of the upper and lower needle plates according to the desired pitch, a two-sided air vent structure can be produced in the cross section of the two-layer fabric. In another example, two sewn layers of fabric are stacked one on top of the other and then passed through a single-sided needle punch machine to produce a one-sided air vent structure in the cross section of the two-layer fabric.

[0042] Depending on the needs of different products, two-layer stitched fabrics (e.g., an upper fabric and a lower fabric) can be stacked in different combinations. In one embodiment, a third layer of upper fabric (e.g., 206) is stacked on top of a first layer of lower fabric (e.g., 202), and then the stack is passed through a forward / reverse needle punch machine to produce a two-layer fabric with a double-sided ventilation groove structure, as shown in FIG. 7(a). In another embodiment, a third layer of upper fabric (e.g., 206) is stacked on top of a third layer of lower fabric (e.g., 206), and then the stack is passed through a forward / reverse needle punch machine to produce a two-layer fabric with a double-sided ventilation groove structure, as shown in FIG. 7(b). Similarly, a first layer of upper fabric (e.g., 202) is stacked on top of a first layer of lower fabric (e.g., 202). In another embodiment, the stacked upper and lower fabrics are passed through a single-sided needle punch to produce a two-layer fabric with a single-sided ventilation groove structure. The total weight of the formed two-layer fabric is, for example, 12 to 800 gsm, and the thickness is, for example, 6 to 60 mm.

[0043] In addition, the double-layered fabric can be selected from different material / specification / weight combinations to provide diversified applications, options, designs or functions, and has the advantages of low cost and environmental protection.

[0044] FIG. 8 is a top view of a woven fabric 800 having an air channel structure. The woven fabric 800 includes a stitching structure 810 with a double diamond-like floral pattern. The woven fabric 800 further includes an air channel structure including outwardly facing convex portions 820 and linearly facing inner recesses 830, each of which has two or more needle holes (schematically represented as 840) to enhance the breathability of the fabric. The size, number, and arrangement of the needle holes are not limited to those shown in the figure. In the embodiment shown in FIG. 8, the width W1 of the linearly facing inner recesses is 10 mm, the width W2 of the outwardly facing convex portions is 40 mm, and the widths of the double diamond-like pattern (the diagonal lengths of the diamonds) are 30 mm and 50 mm, respectively. However, the present invention is not limited to this and can be modified as needed. In one embodiment using a double-layer woven fabric, if necessary, continuous dot-style double linear stitching may be added (e.g., by ultrasonic welding) to the edge 832 of the inner recesses 830 to further fabricate the air channel and strengthen the fixation of the double-layer woven fabric.

[0045] The present invention has been described in detail with respect to the above embodiments for a clearer understanding. However, certain changes and modifications can be made within the scope of the appended claims. It should be noted that there are many alternatives for the processing of the embodiments of the present invention. Therefore, the present embodiments are to be regarded as illustrative, not limiting, and the present embodiments should not be limited to the details mentioned herein. [Explanation of symbols]

[0046] 100: Method 102-108: Step 200: Textiles 202:First layer 204:Second layer 206: Third layer 300: Textiles 302: Suture structure 400: Ventilation groove structure 402: Outward convex part 404: Inward recess 406: Edge 600-630: Ventilation groove structure 800: Textile 800 810: Suture structure 820: Outward convex part 830: Inward recess 832: Edge of inner recess 830 840: Needle punched holes D: Pitch W, W1, W2: Width

Claims

1. 1. A woven structure comprising: a first layer including first fibers and having a first needlepunch density; a second layer located below the first layer, the second layer including second fibers and having a second needlepunch density less than the first needlepunch density; a third layer located below the second layer for enhancing fabric isolation; and a stitching structure that stitches together and secures the first layer, the second layer, and the third layer.

2. an air vent groove structure in which, in a cross section, the first layer has a first set of outward convex portions and a first set of inward concave portions, and the third layer has a second set of outward convex portions and a second set of inward concave portions; 10. The woven structure of claim 1, further comprising:

3. 3. The woven structure of claim 2, wherein the first set of outwardly directed peaks have the same first width, the first set of inwardly directed valleys have the same second width, the second set of outwardly directed peaks have the same third width, and the second set of inwardly directed valleys have the same fourth width.

4. 4. The woven structure of claim 3, wherein the first width is substantially equal to the third width and the second width is substantially equal to the fourth width.

5. 4. The woven structure of claim 3, wherein the first width is not equal to the third width and the second width is not equal to the fourth width.

6. 3. The woven structure of claim 2, wherein the first set of outwardly directed ridges have different widths and the second set of outwardly directed ridges have different widths.

7. 7. The woven structure of any one of claims 1 to 6, further comprising: the first fibers having a thickness of 0.5 dtex-15 dtex; and the second fibers having a thickness of 0.5 dtex-15 dtex.

8. The woven structure of any one of claims 1 to 6, wherein the second layer and the first layer are bonded at the second needlepunch density.

9. Further, the first layer or the third layer has a ventilation groove structure in which, in a cross section, a first set of convex portions facing outward and a first set of concave portions facing inward; 2. The woven structure according to claim 1, comprising:

10. 10. The woven structure of claim 9, wherein the first set of outwardly directed peaks have the same first width and the first set of inwardly directed valleys have the same second width.

11. 10. The woven structure of claim 9, wherein the first set of outwardly directed convex portions have different widths.

12. the first layer having the first set of outwardly directed peaks and the first set of inwardly directed valleys, the woven structure further comprising: a fourth layer underlying the third layer, the fourth layer comprising the first fibers and having a first needlepunch density; a fifth layer below the fourth layer, the fifth layer comprising second fibers and having a second needlepunch density; a sixth layer located below the fifth layer for enhancing isolation of the fabric; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; 10. The woven structure of claim 9, wherein the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions in a cross section of the air channel structure.

13. the first layer having the first set of outwardly directed peaks and the first set of inwardly directed valleys, and the woven structure further comprising: a fourth layer located below the third layer for enhancing isolation of the fabric; a fifth layer underlying the fourth layer, the fifth layer comprising second fibers and having a second needlepunch density; a sixth layer underlying the fifth layer, the sixth layer comprising the first fibers and having the first needlepunch density; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; 10. The woven structure of claim 9, wherein the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions in a cross section of the air channel structure.

14. the third layer having the first set of outwardly directed peaks and the first set of inwardly directed valleys, and the woven structure further comprising: a fourth layer positioned above the first layer, the fourth layer comprising the first fibers and having the first needlepunch density; a fifth layer located above the fourth layer, the fifth layer comprising the second fibers and having the second needlepunch density; a sixth layer positioned above the fifth layer to enhance isolation of the fabric; and a second suture structure that sews and fixes the fourth layer, the fifth layer, and the sixth layer together; 10. The woven structure of claim 9, wherein the sixth layer has a second set of outwardly directed convex portions and a second set of inwardly directed concave portions in a cross section of the air channel structure.

15. 15. The woven structure of any one of claims 12 to 14, wherein the first set of outwardly directed peaks have a same first width, the first set of inwardly directed valleys have a same second width, the second set of outwardly directed peaks have a same third width, and the second set of inwardly directed valleys have a same fourth width.

16. 16. The woven structure of claim 15, wherein the first width is substantially equal to the third width and the second width is substantially equal to the fourth width.

17. 15. The woven structure of any one of claims 9 to 14, wherein the first fibers have a thickness of 0.5 dtex-15 dtex and the second fibers have a thickness of 0.5 dtex-15 dtex.

18. 12. The woven structure of any one of claims 9 to 11, wherein the second layer and the first layer are bonded at the second needlepunch density.

19. 15. The woven structure of claim 12 or 14, wherein the second layer and the first layer are bonded at the second needlepunch density, and the fifth layer and the fourth layer are bonded at the second needlepunch density.

20. 14. The woven structure of claim 13, wherein the second layer and the first layer are bonded at the second needlepunch density, and the sixth layer and the fifth layer are bonded at the second needlepunch density.

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