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 particularly to a fabric having a vent groove structure.

Background Art

[0002] With the development of synthetic materials and manufacturing technology, insulating materials having any one of functions such as heat insulation, sound insulation, filtration and the like have been widely applied to many products. For example, depending on their properties, insulating materials are applied to the following products and / or fields including, but not limited to, cold-proof articles, heat insulation for industry / construction, and sound insulation.

[0003] As a conventional production method for fabrics used in currently commercially available insulating materials, first, a chemical resin is spray-coated onto a fiber web or mixed hot-melt cotton, and then the mixture is put into a large high-temperature dryer to dry and shape the chemical resin. Such a production method requires the use of a large amount of chemical resin to provide high-temperature drying by means of a crucible or a combustor, and also has to consume a large amount of fuel. In addition, the above-mentioned manufacturing method generates a large amount of carbon dioxide, waste gas, waste water pollution and the like, and such a high-temperature, polluted environment is a health concern for producers.

Summary of the Invention

[0004] In view of various problems caused by the above-mentioned conventional production techniques, the inventor of the present application provides a fabric having a vent groove structure and a method for manufacturing the same. According to this method, there is no need to use a chemical resin, a large high-temperature dryer or the like, the drying process required for resin and hot-melt cotton can be omitted, and the method has the advantage that the product can be combined with various long-fiber nonwoven fabrics / short fibers or long filaments / film materials. Therefore, the fabric of the present invention has multifunctional and breathable effects, and achieves the environmental protection goals of no chemical resin use, energy saving and zero carbon emission.

[0005] The present invention relates to a woven fabric structure and includes: a first layer containing first fibers and having a first needle punch density; a second layer located below the first layer and containing second fibers and having a second needle punch density less than the first needle punch density; a third layer located below the second layer and for reinforcing the isolation of the fabric; a stitching structure for stitching and fixing the first layer, the second layer and the third layer together; and a ventilation groove structure in which, in a cross-section, the first layer has a convex portion facing outward toward the first set and a concave portion facing inward toward the first set, and the third layer has a convex portion facing outward toward the second set and a concave portion facing inward toward the second set.

[0006] The outward-facing protrusions of the first pair have the same first width, the inward-facing recesses of the first pair have the same second width, the outward-facing protrusions of the second pair have the same third width, and the inward-facing recesses of the second pair have the same fourth width.

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

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

[0009] The outward-facing protrusions of the first set have different widths, and the outward-facing protrusions of the second set have different widths.

[0010] The thickness of the first fiber is 0.5 dtex to 15 dtex, and the thickness of the second fiber is 0.5 dtex to 15 dtex.

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

[0012] Furthermore, In cross-section, the first layer or the third layer comprises a ventilation groove structure having a convex portion facing outward from the first pair and a concave portion facing inward from the first pair.

[0013] The outward-facing protrusions of the first pair have the same first width, and the inward-facing recesses of the first pair have the same second width.

[0014] The outward-facing protrusions of the first pair have different widths.

[0015] The fabric structure wherein the first layer has a convex portion facing outward and a concave portion facing inward, and further, A fourth layer located below the third layer, containing the first fiber and having the first needle punch density, A fifth layer located below the fourth layer, containing a second fiber and having a second needle punch density, A sixth layer located below the fifth layer, for reinforcing the isolation of the fabric, and The present invention comprises a second suture structure for suturing and fixing the fourth, fifth, and sixth layers, In the cross-section of the ventilation groove structure, the sixth layer has a convex portion facing outward to the second set and a concave portion facing inward to the second set.

[0016] The first layer has a convex portion facing outward and a concave portion facing inward, and the fabric structure further comprises A fourth layer located below the third layer, for reinforcing the isolation of the fabric, A fifth layer located below the fourth layer, containing a second fiber and having a second needle punch density, A sixth layer located below the fifth layer, containing the first fiber and having the first needle punch density, and The present invention comprises a second suture structure for suturing and fixing the fourth, fifth, and sixth layers, In the cross-section of the ventilation groove structure, the sixth layer has a convex portion facing outward to the second set and a concave portion facing inward to the second set.

[0017] The third layer has a convex portion facing outward from the first pair and a concave portion facing inward from the first pair, and further, A fourth layer located above the first layer, containing the first fiber and having the first needle punch density, a fifth layer positioned above the fourth layer, comprising said second fibers and having said second needle punch density; a sixth layer positioned above the fifth layer, for enhancing isolation of said textile fabric, and a second stitching structure for stitching and fixing said fourth layer, said fifth layer and said sixth layer, in a cross-section of said vent groove structure, said sixth layer has a second set of outward convex portions and a second set of inward concave portions.

[0018] the outward convex portions of the first set all have the same first width, the inward concave portions of the first set all have the same second width, the outward convex portions of the second set all have the same third width, and the inward concave portions of the second set all have the same fourth width.

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

[0020] the fineness of said first fibers is 0.5 dtex to 15 dtex, and the fineness of said second fibers is 0.5 dtex to 15 dtex.

[0021] said second layer and said first layer are bonded at said second needle punch density.

[0022] said second layer and said first layer are bonded at said second needle punch density, and said fifth layer and said fourth layer are bonded at said second needle punch density.

[0023] said second layer and said first layer are bonded at said second needle punch density, and said sixth layer and said fifth layer are bonded at said second needle punch density.

[0024] These and other features of the disclosed embodiments will be described in detail below with reference to the related drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] [Figure 1] It is a flow chart showing a method for manufacturing a breathable textile fabric. [Figure 2] This is a schematic diagram of a cross-section of a textile. [Figure 3] This is a schematic diagram of a cross-section of a woven fabric having a sutured structure. [Figure 4] This is a schematic diagram of a cross-section of a fabric having a ventilation groove structure. [Figure 5(a)-(d)] This 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)] This is a schematic diagram of a cross-section of a single-layer fabric with different groove arrangements. [Figure 7(a)-(b)] These are schematic diagrams of cross-sections of two different two-layer fabrics having a grooved structure. [Figure 8] This is a top view of a woven fabric having a sutured structure and a grooved structure. [Modes for carrying out the invention]

[0026] In the following description, several specific details are provided to ensure a thorough understanding of the examples. The examples described herein may be carried out without some or all of these specific details. Regarding other circumstances, conventional processing operations are not described in detail so as not to unnecessarily obscure the disclosed examples. While specific examples are used to illustrate the examples disclosed herein, it is clear that the examples are not limited to these disclosed examples.

[0027] Figure 1 shows the method 100 for manufacturing a breathable fabric according to the present invention, and will be explained below using Figures 2 to 7.

[0028] Figure 2 shows a schematic diagram of a fabric 200, which is 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 in Figure 1, a first fiber having a predetermined fiber specification and weight is formed into a fiber web, and then punched using a needle punching machine, for example, 50 to 300 punches / cm. 2A single-sided high-density needle punching process is performed. High-density needle punching has the effect of increasing the entanglement of fibers, and the originally fluffy and weak fiber web is tightly and firmly entangled to produce a thin, flat, and structurally strong first layer 202.

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

[0031] In step 104 of manufacturing method 100, a fiber web is formed with a second fiber having a predetermined fiber specification and weight, and then the reverse side is subjected to low-density needle punching using a reverse needle punching machine (for example, 3-50 punches / cm²). 2 The needle punch density is either low or zero, so the effect of interfiber entanglement is reduced. Thus, 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 fiber web, then laminated with the first layer 202, and further low-density needle punching is performed using an anti-needle punching machine. In this case, the second layer and the first layer are bonded at a low needle punch density.

[0032] In one embodiment, the material of the second fiber may be PP / PET short or long fibers, the fiber thickness may be 0.5 dtex to 15 dtex, and the length may be 31 mm to infinite length. 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, resulting in high structural strength and isolation. The second layer has a low needle punch density, which maintains the bulkiness, flexibility, and support of the fibers, while also increasing air volume and heat retention. Therefore, combining the first and second layers offers 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 create the benefits of even more multifunctional combinations. For example, fibers that can be mixed include hollow fibers, elastic fibers, regenerated fibers, two-component fibers, polylactic acid fibers, and natural fibers.

[0035] In step 106 of manufacturing method 100, the first layer 202, the second layer 204, and the third layer 206 are sewn together and fixed to form a fabric 300 having a sewn structure 302 (as shown in Figure 3). Of these, the third layer enhances the isolation (e.g., isolation of air, moisture, etc.) and heat retention of the present invention and can prevent fiber shedding. The spaces fixed in each layer in this manner allow each fiber layer to move freely within the space in which it is fixed. In dynamic mode, each fiber can move freely due to vibration, resulting in increased airflow or heat dissipation. In static mode, the fiber layers cease activity and each fiber layer has a different natural upright or stretched form, causing the fiber layers to naturally unfold and become bulkier, increasing the amount of air and heat retention effect. In this way, the flexibility of the fabric can be increased and its rigid physical properties can be improved. In contrast, conventional isolation materials fix the fibers as a whole into a sheet structure, so the desirable effects of the present invention cannot be achieved.

[0036] In one embodiment, the material of the third layer may be PP meltblown nonwoven fabric, and its weight may be 10 to 100 gsm. In other embodiments, the material of the third layer may be PP / PET spunbond nonwoven fabric, waterproof film, metal-plated film, etc. In one embodiment, the suture structure is formed by ultrasonic continuous dot fusion and has a double diamond lattice floral pattern. In other embodiments, it can be fixed by suture with a heat bond roll or high frequency. In other embodiments, the suture structure may be a dotted geometric pattern or an even number pattern. In addition, when sutured and fixed, the protection of the first layer can be enhanced by selectively adding a fourth layer near the first layer. The material of the fourth layer may be a nonwoven fabric, for example, a long filament nonwoven fabric, and its weight may be 9 to 20 gsm.

[0037] Returning to Figure 1, in step 108, the stitched fabric (for example, fabric 300 in Figure 3) is passed through a needle punching device to create a ventilation groove structure. In one example, the stitched fabric was passed through a single-sided needle punch, and needles were positioned on the upper or lower needle plate at a desired pitch to create a single-sided ventilation groove structure 400 (shown in Figure 4) in the cross-section of the fabric. The ventilation groove structure 400 includes outward-facing convex portions and inward-facing recesses 404. The needle punching intermittently interlocks and fixes the fibers of the first, second, and third layers, forming inward-facing recesses toward the interior of the fabric, while simultaneously creating numerous needle-punched voids in the inward-facing recesses. Therefore, the inward-facing recesses can increase the breathability of the fabric. When the inward-facing recesses 404 are punctured by the needle punch, the fibers of the first layer enter the second and third layers, and edges 406 are created on the outside of the first and third layers. Outward-facing protrusions that are not needle-punched maintain a certain thickness of fiber bulk, achieving a heat-insulating and insulating effect. By controlling the needle-punching density, the groove depth and breathability can be adjusted. The higher the needle-punching density, the thinner and firmer the fiber layer becomes, and the larger the needle pores, the more desirable breathability is obtained. In the embodiment shown in Figure 4, the first layer 202 has outward-facing protrusions and inward-facing recesses, and the third layer is held almost flat. In another embodiment, the third layer has outward-facing protrusions and inward-facing recesses, and the first layer is held almost flat. The total weight of the formed fabric is approximately 60-400 gsm, and the thickness is approximately 3-30 mm.

[0038] In another example, a single layer of stitched fabric was passed through a forward / backward needle punching machine, and needles were positioned on the upper or lower needle plates at a desired pitch to create a double-sided ventilation groove structure in the cross-section of the fabric. Unlike the arrangement of general needle plates, the needle hole size and position of the stress guide plate and peeling guide plate of such a needle punching device are different. In particular, the upper and lower needle plates and guide plates require a high-density design and are used to create ventilation grooves. The design of the double-sided groove structure improves the structural strength, elasticity, and flexibility of the fabric, and improves air circulation and reflective effect within the groove structure, thereby improving the drawbacks of conventional thick and heavy cotton layers, which are thick, stiff, and not flexible.

[0039] When using a forward / reverse needle punching device, the needles on the upper and lower needle plates are adjusted to the same width W and the same pitch D (shown in Figure 5(a)) according to the different requirements of the product, forming inward-facing recesses of the same width on both the upper and lower surfaces (as shown in the ventilation groove structure 600 in Figure 6(a)). In this way, the ventilation effect on both the upper and lower sides of the fabric becomes almost the same. Alternatively, the needles on the upper and lower needle plates are adjusted to different widths and different pitches (shown in Figure 5(b) or 5(c)) to form inward-facing recesses of different widths on both the upper and lower surfaces (as shown in the ventilation groove structure 610 in Figure 6(b) or the ventilation groove structure 620 in Figure 6(c)). By making the ventilation effect on both sides of the fabric different in this way, one side becomes better at heat retention and the other side at breathability and heat dissipation. Alternatively, by adjusting the needles on the upper and lower needle plates to the same width but different pitches (shown in Figure 5(d)), outward-facing protrusions of different widths (as shown in the ventilation groove structure 630 in Figure 6(d)) are formed. Depending on the ventilation requirements, the groove structure can be designed with various widths, allowing for better ventilation in some areas with more inward-facing recesses and better heat retention and isolation in other areas with fewer inward-facing recesses.

[0040] The depth of the inward-facing recesses varies depending on the needle punch density, fiber thickness, and material. While this is merely an example, in a ventilation groove structure, the width of the inward-facing recesses is typically 2.5-100 mm, the width of the outward-facing protrusions is 5-300 mm, and the needle punch density is 10-200 punches / cm². 2 That's fine. All of the above parameters can be adjusted as needed.

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

[0042] Depending on the different product needs, two layers of woven fabric (e.g., upper and lower layers) are laminated using different combination methods. In one embodiment, the third layer of the upper layer (e.g., 206) is laminated on top of the first layer of the lower layer (e.g., 202), and then the fabric is fed into a forward / reverse needle punching machine to form a two-layer fabric with a double-sided ventilation groove structure as shown in Figure 7(a). In another embodiment, the third layer of the upper layer (e.g., 206) is laminated on top of the third layer of the lower layer (e.g., 206), and then the fabric is fed into a forward / reverse needle punching machine to form a two-layer fabric with a double-sided ventilation groove structure as shown in Figure 7(b). Similarly, the first layer of the upper layer (e.g., 202) is laminated on top of the first layer of the lower layer (e.g., 202), and production is carried out. In yet another embodiment, after the upper and lower layers are laminated, they are passed through a single-sided needle punch to form 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, double-layered fabrics offer diverse applications, options, designs, and functions by selecting different material / specification / weight combinations, while also providing the advantages of low cost and environmental protection.

[0044] Figure 8 is a top view of a fabric 800 having a ventilation groove structure. The fabric 800 includes a stitched structure 810 having a double diamond lattice floral pattern. The fabric 800 further has a ventilation groove structure including outward-facing protrusions 820 and straight inward recesses 830, the inward recesses having two or more needle holes (figure 840) to increase 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 Figure 8, the width W1 of the straight inward recess is 10 mm, the width W2 of the outward-facing protrusion is 40 mm, and the widths of the double diamond lattice (diagonal length of the diamond) are 30 mm and 50 mm, respectively. However, the present invention is not limited thereto and can be modified as needed. In one embodiment using a two-layer fabric, if necessary, a continuous dot type double straight stitch line may be added to the edge 832 of the inward recess 830 (for example by ultrasonic fusion) to further process the ventilation grooves and strengthen the fixation of the two-layer 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 categories of the attached claims. It should be noted that there are many alternative methods for the processing methods of the embodiments of the present invention. Therefore, the embodiments of this application are to be considered for illustrative purposes only and are not limited thereto. Furthermore, the embodiments of this application 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: Textile 302: Suture structure 400: Ventilation groove structure 402: Outward-facing convex part 404: Inward-facing recess 406: Edge 600-630: Ventilation groove structure 800: Textile 800 810: Suture structure 820: Outward-facing convex part 830: Inward-facing recess 832: Edge of inner recess 830 840: Needle Punch Cavity D: Pitch W, W1, W2: Width

Claims

1. A fiber sheet structure comprising a first layer, a second layer and a third layer, A first layer containing a first fiber and having a first needle punch density, A second layer located below the first layer, containing a second fiber and having a second needle punch density lower than the first needle punch density, A third layer is located below the second layer to further reinforce the isolation of the fiber sheet, A suture structure for suturing and fixing the first layer, the second layer, and the third layer, In a cross-section, the first layer has a convex portion facing outward in the first set and a concave portion facing inward in the first set, and the third layer has a convex portion facing outward in the second set and a concave portion facing inward in the second set, forming a ventilation groove structure. It has, In the recesses extending inward of the first set, the first fibers are present in the second layer and the third layer, and in the recesses extending inward of the second set, the material of the third layer is present in the second layer and the first layer. A fiber sheet structure characterized by the following features.

2. The fiber sheet structure according to claim 1, characterized in that the outward-facing protrusions of the first set have the same first width, the inward-facing recesses of the first set have the same second width, the outward-facing protrusions of the second set have the same third width, and the inward-facing recesses of the second set have the same fourth width.

3. The fiber sheet structure according to claim 2, characterized in that the first width is substantially equivalent to the third width, and the second width is substantially equivalent to the fourth width.

4. The fiber sheet structure according to claim 2, characterized in that the first width is not equivalent to the third width and the second width is not equivalent to the fourth width.

5. The fiber sheet structure according to claim 1, characterized in that the outward-facing protrusions of the first set have different widths, and the outward-facing protrusions of the second set have different widths.

6. The fiber sheet structure according to any one of claims 1 to 5, further comprising the first fiber having a thickness of 0.5 dtex-15 dtex and the second fiber having a thickness of 0.5 dtex-15 dtex.

7. The fiber sheet structure according to any one of claims 1 to 5, wherein the second layer and the first layer are bonded together at the second needle punch density.

8. A fiber sheet structure comprising a first layer, a second layer and a third layer, A first layer containing a first fiber and having a first needle punch density, A second layer located below the first layer, containing a second fiber and having a second needle punch density lower than the first needle punch density, A third layer is located below the second layer to further reinforce the isolation of the fiber sheet, A suture structure for suturing and fixing the first layer, the second layer, and the third layer, In a cross-section, the first layer or the third layer has a ventilation groove structure having a convex portion facing outward from the first pair and a concave portion facing inward from the first pair, Equipped with, When the first layer has a convex portion facing outward and a concave portion facing inward, the first fiber is present in the second layer and the third layer in the concave portion facing inward of the first pair. When the third layer has a convex portion facing outward of the first pair and a concave portion facing inward of the first pair, in the concave portion facing inward of the first pair, the material of the third layer is present in the second layer and the first layer. A fiber sheet structure characterized by the following features.

9. The fiber sheet structure having a convex portion facing outward and a concave portion facing inward of the first pair, wherein the fiber sheet structure further comprises A fourth layer located below the third layer, containing the first fiber and having the first needle punch density, A fifth layer located below the fourth layer, containing a second fiber and having a second needle punch density, A sixth layer located below the fifth layer to further reinforce the isolation of the fiber sheet, and The fiber sheet structure according to claim 8, further comprising a second suture structure for suturing and fixing the fourth layer, the fifth layer and the sixth layer, wherein in the cross-section of the ventilation groove structure, the sixth layer has a convex portion facing outward to the second set and a concave portion facing inward to the second set.

10. The first layer has a convex portion facing outward and a concave portion facing inward, and the fiber sheet structure further comprises A fourth layer located below the third layer to further reinforce the isolation of the fiber sheet, A fifth layer located below the fourth layer, containing a second fiber and having a second needle punch density, A sixth layer located below the fifth layer, containing the first fiber and having the first needle punch density, and The fiber sheet structure according to claim 8, further comprising a second suture structure for suturing and fixing the fourth layer, the fifth layer and the sixth layer, wherein in the cross-section of the ventilation groove structure, the sixth layer has a convex portion facing outward to the second set and a concave portion facing inward to the second set.

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