A textile surface and production method developed for outdoor sun shading fabric applications

Abstract

Disclosed is a PVC-free triple yarn developed for zipped roller blind applications and a roller blind fabric woven from this yarn. The PVC-free roller blind fabric for outdoor sun shading systems is woven from a triple yarn twisted tertiary yarn over twisted primary and secondary colored yarns.

Description

FIELD OF THE INVENTION

[0001] The invention relates to textile surfaces used in outdoor sun shading systems.

[0002] The invention relates specifically to a PVC-free yarn developed for zipped outdoor shading applications and an outdoor shading fabric woven from this yarn.STATE OF THE ART

[0003] The demand for especially recycling and environmentally friendly products has increased rapidly as a result of the sustainability and ecological approach concepts in the textile sector. Zipped blinds, especially used in outdoor applications, are roller blind systems that are very easy to use and have a robust structure and are resistant to all environmental conditions. It has the feature of being an improved product for protection, shading and as an alternative to different previously used products.

[0004] It is known that the yarns used in these product groups are covered with PVC material, which is also known to be harmful to human health. The possibility of shedding in flakes over time, as well as the fact that the product is not suitable for recycling also creates disadvantages. In addition, during the assembly of the blind, using the fabric containing glass fiber yarn, dusting of the fibers due to cutting process also poses a risk to human health and creates difficulties in operational processes.

[0005] For example, utility model application numbered TR 2018 / 17954 discloses the use of at least one PVC-coated yarn of narrow woven fabric, which is produced for use in tarpaulins, greenhouses, tents, ship sails.

[0006] In the production method of PVC coated yarns, a carrier (core) yarn is passed through the melt and the yarn is covered (FIGS. 1-2). While all kinds of natural, synthetic threads, including but not limited to glass fiber (GF), polyester, nylon and also their combinations, are used in the inner yarn, the outer coating melt is polyvinyl chloride (PVC).

[0007] In this yarn production method, which is not suitable for a standard production facility, special machines suitable for the system are required to weave PVC coated yarns and turn them into products. Chemical waste is generated since the process of the final coated yarn is a chemical process, in this case it is important for the facility to be integrated.

[0008] As a result due to the above mentioned disadvantages and the insufficiency of the current solutions regarding the subject matter, a development is required to be made in the relevant technical field.Aim of the Invention

[0009] The invention aims to solve the above mentioned disadvantages by being inspired from the current conditions.

[0010] The main aim of the present invention is to produce PVC-free, high-strength and UV-resistant sun shading fabric for use in outdoor roller blind systems, especially zipped roller blind systems. An odorless and environmentally friendly roller blind fabric is provided as it does not contain any harmful chemicals such as PVC, formaldehyde and halogen with the help of the triple composite yarn structure developed.

[0011] An aim of the invention is to provide an ecological production method that does not require any dyeing process in fabric production due to the fact that the developed triple yarn structure yarns (A and B yarns) are high-strength, UV-resistant and produced in dyed form from masterbatch drawing. There is no water and chemical consumption for dyeing, and no waste is generated, and an economical and ecological product is provided.

[0012] Another aim of the invention is to provide yarn that can be used in all kinds of warp and weaving machines according to the specified weaving pattern and fabric construction by passing the colored yarns (A and B yarns) obtained from the masterbatch drawing together with specially produced yarns (C yarn) through special twisting and fixation processes. The woven fabric is processed through the stenter and hardened to desired value by the effect of temperature, and at the end of the process, the textile surface designed for the zipped roller blind fabric to be used becomes ready.

[0013] An aim of the invention is to produce zipped roller blind fabric with a method that provides cost advantage in production and does not have any supply problem. The final product consists entirely of a textile surface and does not contain harmful chemicals. It is totally recyclable, and there is no water consumption nor is any chemical waste generated during production processes. Compared to the existing fabrics made of PVC coated glass fiber, polyester or other synthetic threads, the fabrics produced within the scope of the invention provide better breaking strength, tear resistance and abrasion (wear) resistance performance.

[0014] An aim of the invention is to provide users with various advantages such as air circulation, light control and heat insulation, protection against UV, UVA and UVB rays, protection from the burning effect of the sun, wind and rain, thanks to its micro-ventilation texture with the roller blind fabric produced within the scope of the invention as well as being modern and aesthetic.

[0015] In order to fulfill the above-described aims, the invention is a PVC-free roller blind fabric for outdoor sun shading systems, characterized by comprising triple yarn; consisting of twisted tertiary yarn on twisted primary and secondary colored yarns in its weaving.

[0016] In order to fulfill the above-described aims, the invention is a PVC-free roller blind fabric production method for outdoor sun shading systems; comprises the following process steps:

[0017] (i) Drawing of high-strength, UV-resistant, colored primary and secondary yarns on spinning machines,

[0018] (ii) Plying the drawn yarns and preparing them for twisting,

[0019] (iii) Twisting of primary and secondary colored yarns and fixing,

[0020] (iv) Re-twisting of fixed yarn together with the tertiary yarn and fixing,

[0021] (v) Weaving the triple yarn, which is ready for weaving, in a suitable construction with the predetermined weave pattern and density value,

[0022] (vi) Obtaining roller blind fabric by finishing treatment of the woven fabric.

[0023] The characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings and therefore the evaluation shall be made by taking these figures and the detailed description into consideration.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1: Sectional view of PVC coated synthetic threads like glass fiber (GF), polyester, etc. according to the present technique.

[0025] FIG. 2: Side cross-sectional view of PVC coated synthetic threads like glass fiber (GF), polyester, etc. according to the present technique.

[0026] FIG. 3: View of A and B yarns according to the invention.

[0027] FIG. 4: View of the plied of yarns A and B yarns according to the invention.

[0028] FIG. 5: View of twisting of yarn C on the plied yarns A and B according to the invention.

[0029] FIG. 6: View of the weaving pattern of the exemplary fabric construction according to the invention.

[0030] FIG. 7: A schematic view of the plain weave structure according to the invention.

[0031] FIG. 8: A yarn cross-sectional view of the plain weave structure of the composite yarn according to the invention.

[0032] FIG. 9: Schematic view of the plying process of A and B yarns according to the invention.

[0033] FIG. 10: Schematic view of the twisting process of A+B yarns according to the invention.

[0034] FIG. 11: Schematic view of the twisting process of A+B+C yarns in a fancy twisting machine according to the invention.DESCRIPTION OF THE PART REFERENCESA: primary yarn

[0036] B: secondary yarn

[0037] C: tertiary yarn

[0038] GF: glass fiber

[0039] PVC: polyvinyl chlorideDETAILED DESCRIPTION OF THE INVENTION

[0040] In this detailed description, the preferred embodiments of the inventive roller blind fabric is described by means of examples only for clarifying the subject matter.

[0041] The present invention is based on the development of functional technical textiles and relates to the PVC-free roller blind fabric for use in “zipped roller blind” systems and to the production method thereof.

[0042] PVC-free roller blind fabric for outdoor sun shading systems in its most basic form comprises triple yarn consisting of twisted yarn on twisted primary and secondary colored yarns in its weaving (FIG. 3-5).

[0043] The production method of PVC-free roller blind fabric for outdoor sun shading systems includes the following processing steps in its most basic form:

[0044] (i) Drawing of high-strength, UV-resistant, colored primary and secondary yarns on spinning machines,

[0045] (ii) Plying the drawn yarns and preparing them for twisting

[0046] (iii) Twisting of primary and secondary colored yarns and fixing,

[0047] (iv) Re-twisting of fixed yarn together with the tertiary yarn and fixing,

[0048] (v) Weaving the triple yarn, which is ready for weaving, in a suitable construction with the predetermined weave pattern and density value,

[0049] (vi) Obtaining roller blind fabric by finishing treatment of the woven fabric.

[0050] In the preferred application of the present invention, high-strength, UV-resistant colored primary yarn (A) and secondary yarn (B) are drawn in the drawing machines and formed into colored yarn (FIG. 3). Colored primary yarn (A) and secondary yarn (B) are plied (doubling) in the yarn doubling machine (FIG. 9) and turned into ready-to-twist yarn wrapped in cop. Doubling is the direct folding of threads without twisting. The task of the doubling machine (FIG. 9) is to prepare the twisting machine by plying (folding / doubling) the single-ply yarns that need to be twisted on a bobbin at the same tension, and to provide ease of operation in all subsequent processes by winding in bobbin form and long lengths.

[0051] Then, twisted yarn (A+B) is produced by twisting in S direction with 100-500 TM (tours / meter) in the twisting machine, but not limited to this. Twisting is made to increase the strength of the yarns (flat twist) or to gain different characters (fancy twist). The amount of twisting required to hold the yarns together; depends on the diameter, type and length of the yarn.

[0052] According to an embodiment of the present invention, the primary and secondary yarns are preferably colored polyester yarns, and the tertiary yarn is bicomponent yarn. Bicomponent fiber production is one of the synthetic fiber production methods based on the extrusion of polymers with at least two or more polymer components, either using same or different polymers on each component (PTT, PET, PP, PA, PE, PVP, PEG, PVDF, etc.). With this method, many different properties can be imparted to the fibers. Tertiary yarns are drawn on bicomponent spinning machines with different drawing temperatures, and then goes through a twisting process. Then, the colored primary and secondary yarns (A+B) and the tertiary yarn (C) are twisted together in a certain amount of twist round and the winding process is performed.

[0053] Finally, fixation is applied to the triple yarn (A+B+C) wound on the bobbin and then becomes a ready-to-use composite yarn. Fixation is made for the purposes of gaining strength, preventing static electricity, fixing the twist especially for highly twisted and multi-ply yarns, and ensuring the yarn to run comfortably.

[0054] The construction of the fabric and the technical performance values of the yarns are the most important factors affecting the strength. The raw fabric is woven according to the desired weft-warp densities, fabric widths and fabric construction by using prepared yarns. (FIG. 6). After treatment of raw fabric with finishing processes, the final product is formed. Parameters such as fabric width, weight and shrinkage can be easily adjusted.

Claims

1. A PVC-free fabric for outdoor sun shading systems, comprising triple yarn comprising of twisted tertiary yarn on twisted primary and secondary colored yarns in its weaving.

2. A production method of PVC-free roller blind fabric for outdoor sun shading systems, comprising the following processing steps:(i) drawing of high-strength, UV-resistant, colored primary and secondary yarns on spinning machines,(ii) plying the drawn yarns and preparing them for twisting,(iii) twisting of primary and secondary colored yarns and fixing,(iv) re-twisting of fixed yarn together with the tertiary yarn and fixing,(v) weaving the triple yarn, which is ready for weaving, in a suitable construction with the predetermined weave pattern and density value,(vi) obtaining roller blind fabric by finishing treatment of the woven fabric.

3. The method according to claim 2, wherein in process step (iii) the yarns are, but not limited to, 1200 denier, in the S twist direction with 100-500 TM.

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