Fiber structure and method for producing the same

Abstract

To provide a fiber structure in which a single yarn of a glass fiber can be applied to a complicated woven fabric such as a Jacquard weaving; and to provide a manufacturing method of the fiber structure.SOLUTION: There is provided a fiber structure formed of a Jacquard weaving and including a plurality of warp yarns and a plurality of weft yarns intersecting with the plurality of warp yarns. The plurality of warp yarns are made of a resin, and the plurality of weft yarns include a single yarn of a glass fiber.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a fiber structure and a method for manufacturing the same.

Background Art

[0002] For example, Patent Document 1 (Japanese Unexamined Patent Application Publication No. 2023-63052) discloses a composite body that is excellent in the feeling of being worn on the body and has excellent adhesiveness between a resin molded product and a fiber structure. The composite body includes a resin molded product containing a thermoplastic resin, and a fiber structure that is at least partially in contact with the resin molded product and has an elongation at break of 50.0% or more. Here, the fiber constituting the fiber structure may be glass fiber, and the form of the fiber structure may be a woven fabric.

[0003] In Patent Document 1, although it is not specified in what form the glass fiber is used, since the single filament of glass fiber is strong but fragile in itself, it is not suitable for the manufacturing process in a situation where stress such as bending or stretching is applied. For example, even if it is used on a loom, it is used for simple woven fabrics such as plain weave, twill weave, or baby weave, but in fact, it is not used for complex woven fabrics such as jacquard weave.

[0004] In addition, woven fabrics using glass fiber may be various non-woven fabrics or woven fabrics in which both warp and weft are made of glass fiber. Generally, their use is limited to being pasted on the back side for reinforcing the object to be reinforced, and the texture obtained by using the glass fiber has not been actively utilized for the texture of the final product or the appearance of the surface.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] Contrary to the common general knowledge in the prior art of this kind, the inventors of the present invention attempted to supply a glass fiber yarn and a resin yarn to a jacquard loom to see if a woven fabric could be produced. Contrary to expectations, a woven fabric could be produced. Further, when a part of the resin yarn was made into a heat-shrinkable yarn and heated, it was found that a texture and appearance of the fabric never seen before could be obtained depending on the conditions.

[0007] Based on the above, the present invention provides a fiber structure body made of a jacquard weave in which a single glass fiber yarn can be used for a complicated woven fabric such as a jacquard weave, and a manufacturing method thereof.

Means for Solving the Problem

[0008] The present invention obtained based on the above-described findings is a fiber structure body having a plurality of warp yarns and a plurality of weft yarns that intersect with the plurality of warp yarns, wherein the plurality of warp yarns are made of resin, and the plurality of weft yarns include single glass fiber yarns, and provides a fiber structure body made of a jacquard weave characterized by the above.

[0009] In the fiber structure body of the present invention having the above configuration, a plurality of the plurality of warp yarns are shrinkable warp yarns, and it is preferable that the shrinkable warp yarn has a skipping portion that skips a predetermined number of adjacent weft yarns at at least one location in the length direction thereof.

[0010] In the fiber structure body of the present invention having the above configuration, it is preferable that the single glass fiber yarns are included at 20 to 120 per 1 cm in width of the fabric of the fiber structure body. is preferable.

[0011] Further, in the fiber structure body of the present invention having the above configuration, it is preferable that the single glass fiber yarns are 30 to 3000 denier.

[0012] Also, the present invention includes a step of weaving a fabric with a plurality of warp threads and a plurality of weft threads that intersect with the plurality of warp threads in a preset pattern, and a step of applying a specific treatment to the woven fabric, and is a method for manufacturing a fiber structure, wherein the plurality of warp threads are made of resin, and provides a method for manufacturing a fiber structure made of jacquard weave, characterized by the above.

[0013] In the method for manufacturing a fiber structure of the present invention having the above configuration, a plurality of some of the plurality of warp threads are shrinkable warp threads, the shrinkable warp threads have a skipping portion that skips a predetermined number of adjacent weft threads at at least one location in the length direction thereof, and it is preferable that the plurality of weft threads include single glass fiber filaments.

Advantages of the Invention

[0014] According to the present invention, it is possible to provide a fiber structure made of jacquard weave and a method for manufacturing the same, in which single glass fiber filaments can be used in a complex fabric such as jacquard weave.

Brief Description of the Drawings

[0015]

Figure 1

Embodiments for Carrying Out the Invention

[0016] Hereinafter, a fiber structure made of jacquard weave and a method for manufacturing the same according to a representative embodiment of the present invention will be described in detail with reference to the drawings. Note that the drawings are for conceptually explaining the present invention, and for ease of understanding, dimensions, ratios, or numbers may be exaggerated or simplified as necessary, and the present invention is not limited thereto.

[0017] 1. Configuration of the fiber structure 1 Referring to FIG. 1, the configuration of the fiber structure 1 made of a Jacquard weave will be described. FIG. 1 is a schematic diagram showing an example of the texture of the fiber structure 1.

[0018] The fiber structure 1 is a fabric made of a woven fabric. That is, the fiber structure 1 has a plurality of warp threads 10 and a plurality of weft threads 20 that intersect with the plurality of warp threads 10. The plurality of warp threads 10 is a general term for normal warp threads (other warp threads) 11 and shrinkable warp threads 12, which will be described later, and are made of resin. Also, the plurality of weft threads 20 is a general term for normal weft threads (other weft threads) 21 and single filaments 22 of glass fiber, and the other weft threads 21 are made of resin. Note that the fabric constituting the fiber structure 1 may be single-layer or double-layer.

[0019] The plurality of warp threads 10 includes normal warp threads 11 and shrinkable warp threads 12. Here, the normal warp threads 11 may be chemical fibers or resin fibers. The normal warp threads 11 can be manufactured from a resin material such as polyester, for example.

[0020] The shrinkable warp threads 12 are those that shrink more in the length direction than the normal warp threads 11 when a specific treatment such as heating is applied, and can also be said to be heat-shrinkable threads. For example, the shrinkable warp thread 12 is composed of a core and a covering thread wound around the outer peripheral side of the core. For the core, a material that shrinks greatly in the length direction when heated at a predetermined temperature, such as polyurethane, can be used. Also, for the covering thread, the same material as the normal warp thread 11, such as polyester, can be used.

[0021] The shrinkable warp threads 12 in the fiber structure 1 have a skipping portion 12A that skips a predetermined number of adjacent weft threads at at least one location in the length direction. The skipping portion 12A may be exposed on the front side of the fiber structure 1 or hidden on the back side. The skipping portion 12A is arranged according to a preset pattern.

[0022] Next, the weft yarn includes single yarns (yarns) 22 of glass fiber (long fiber). For example, single yarns of E glass fiber can be preferably used as the weft yarn, but it is not limited thereto. Also, as the other weft yarn (ordinary weft yarn) 21, a material similar to that of the ordinary warp yarn 11, for example, polyester, can be used.

[0023] In the fiber structure 1, when a specific treatment such as heating is applied, the shrinkable warp yarn 12 shrinks more in the length direction than the ordinary warp yarn 11. At this time, it shrinks greatly at the jump-over part 12A, and the fiber structure 1 shrinks in the warp direction as a whole. Thereby, a three-dimensional shape and pattern are formed on the fiber structure 1 according to a preset pattern. Also, sufficient strength can be ensured by the glass fiber contained in the weft yarn 20. Moreover, the hardness of the fiber structure 1 can be adjusted.

[0024] Next, specific examples of the materials constituting the fiber structure 1 will be given. As the ordinary warp yarn 11, polyester 50 to 150 (preferably 70 to 80) denier (36 filaments) can be used. Also, as the shrinkable warp yarn 12, polyester-wound marlon (adhesive processing) can be used. The shrinkable warp yarn 12 can be 50 to 150 denier. The ratio of the ordinary warp yarn 11 to the shrinkable warp yarn 12 can be about 2000 of the latter to 10000 of the former.

[0025] Also, as the single yarn 22 of glass fiber used as the weft yarn, those of 30 to 3000 denier can be used. The single yarn 22 of glass fiber can utilize a wound and coiled form. Also, about 10 to 50 can be inserted per centimeter in a single-layer fabric, and about 30 to 120 can be inserted per centimeter in a double-layer fabric. If the number of stitches per centimeter is less than 10 or more than 120, it will not form a fabric. That is, if the number of stitches per centimeter is less than 10, it will become thick and the shape stability as a fabric will be impaired, making it difficult to form a fabric. Also, if the number of stitches per centimeter exceeds 120, it will become dense and the fabric will become too rigid, impairing its flexibility and processability, making it difficult to form a practical fabric. Furthermore, in order to more surely obtain the effects of the present invention, it is preferable to use glass fiber single filaments 22 having a denier of 100 to 300 and to set the number of stitches to 20 to 100.

[0026] E glass can be preferably used as the type of glass fiber. The composition of E glass is generally as follows. SiO2 52 - 56 (%) Al2O3 12 - 16 (%) CaO, MgO 20 - 25 (%) R2O 0 - 0.8 (%) B2O3 5 - 10 (%)

[0027] Also, the glass fiber in the present embodiment is a single filament obtained by twisting a strand composed of filaments with a diameter of 4.0 μm to 7.4 μm. In particular, those having the following characteristics can be preferably used. [Glass Fiber Example 1] Filament diameter 5.3 μm Number of filaments 200 Twist number 1.0 / 25 mm Tex count 11.2 g / 1000 m Length per unit mass 89.2 km / kg

[0028] [Glass Fiber Example 2] Filament diameter 6.4 μm Number of filaments 400 Twist number 1.0 / 25 mm Tex count 33.7 g / 1000 m Length per unit mass 29.6 km / kg

[0029] Further, the single filament 22 of the glass fiber may have one rotation (in the Z direction) per 25 mm for a 100 - denier equivalent and one rotation (in the Z direction) per 25 mm for a 300 - denier equivalent.

[0030] 2. Manufacturing method of the fiber structure 1 Next, a method for manufacturing the fiber structure 1 will be described.

[0031] The method for manufacturing the fiber structure 1 includes a step of weaving a fabric with a plurality of warp threads 10 and a plurality of weft threads 20 that intersect with the plurality of warp threads 10 in a preset pattern (weaving step), and a step of applying a specific treatment to the woven fabric. Here, since heating is used as the specific treatment, the latter step is referred to as the heating step. However, as the specific treatment, any treatment that can shrink the shrinkable warp thread 12 may be used, and for example, other treatments such as immersion in chemicals may also be used.

[0032] The warp threads 10 include normal warp threads 11 and shrinkable warp threads 12. Also, the weft threads 20 include single filaments 22 of glass fiber and other weft threads 21. In the weaving step in this embodiment, for example, the warp threads 10 and weft threads 20 in the form of wound bodies are used, and these are supplied to a Jacquard loom for Jacquard weaving. Before hanging the warp threads 10 and weft threads 20 on the loom, the necessary pattern paper preparation, yarn dyeing, and warping are carried out.

[0033] In the heating step, various methods can be adopted as long as they can heat the woven fabric. For example, an iron, steam, a hot water bath, etc. can be used. By applying heat to shrink the shrinkable warp thread 12, the fabric is formed into a three - dimensional structure. These heating conditions can be appropriately adjusted according to the specifications of the fiber structure 1. For example, steam at 100°C to 180°C can be applied to the fiber structure 1 for about 1 second to 1 minute, preferably 2 to 3 seconds to 30 seconds.

[0034] In the fiber structure 1 thus obtained, by means of jacquard weaving technology, it is possible to reproduce a fine and delicate pattern with a high degree of freedom. Since the pattern can be created while changing the fabric texture, not only does the fabric gain a three-dimensional effect and thickness, but the three-dimensional effect is enhanced by the shrinkage of the fabric itself.

[0035] Moreover, the glass fiber of the weft can impart sufficient strength to the fiber structure 1. Moreover, the hardness of the fiber structure 1 can be adjusted by adjusting the composition and heating conditions of the shrinkable warp 12.

[0036] Therefore, the fiber structure 1 can be used for various applications and is applicable to the front side to be decorated. For example, the fiber structure 1 can be utilized for lighting, interior decoration, furniture, etc. In this regard, in the conventional technology, although there has been an instance of passing a yarn containing glass fiber through a loom, it has been limited to application to relatively simple fabrics such as plain weave, twill weave, and crepe weave. That is, conventionally, there has been no idea of performing jacquard weaving using a yarn containing glass fiber. Also, conventionally, a fabric of a yarn containing glass fiber has been used only to the extent of being attached to the back side of an object for reinforcement, etc., and this fiber fabric has not been utilized as a pattern on the front side.

[0037] As described above, the representative embodiments of the present invention have been explained, but the present invention is not limited to such embodiments only, and various design changes are possible, and all aspects of such design changes are also included in the technical scope of the present invention. For example, metal fibers such as aluminum fibers and carbon fibers may be used in combination with glass fibers.

Explanation of Reference Numerals

[0038] 1 Fiber structure (fabric) 11 Normal warp (other warp) 12 Shrinkable warp 12A Jumping-over part 21 Normal weft (other weft) 22 Single filament of glass fiber

Claims

1. A fibrous structure having a plurality of warp threads and a plurality of weft threads that intersect with the plurality of warp threads, wherein the plurality of warp threads are made of resin, the plurality of weft threads include single filaments of glass fiber, a plurality of the warp threads among the plurality of warp threads are shrinkable warp threads, and the shrinkable warp threads are shrunk, characterized by a fibrous structure made of jacquard weave.

2. The shrinkable warp thread has a jumping-over portion that jumps over a predetermined number of adjacent weft threads at at least one location in the length direction thereof, characterizing the fibrous structure according to Claim 1.

3. The single filaments of the glass fiber are included in an amount of 20 to 120 per 1 cm width of the fabric of the fibrous structure, characterizing the fibrous structure according to Claim 1 or 2.

4. The single filaments of the glass fiber are 30 to 3000 denier, characterizing the fibrous structure according to Claim 1 or 2.

5. A step of weaving a fabric with a plurality of warp threads and a plurality of weft threads that intersect with the plurality of warp threads in a preset pattern, and a step of applying a heat treatment to the woven fabric, wherein the method for manufacturing a fibrous structure includes: the plurality of warp threads are made of resin, the plurality of weft threads include single filaments of glass fiber, a plurality of the warp threads among the plurality of warp threads are shrinkable warp threads, and the shrinkable warp threads are shrunk by heat treatment, characterized by a method for manufacturing a fibrous structure made of jacquard weave.

6. The shrinkable warp thread has a jumping-over portion that jumps over a predetermined number of adjacent weft threads at at least one location in the length direction thereof, characterizing the method for manufacturing a fibrous structure according to Claim 5.

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