JP7366530B2 - flat yarn fabric - Google Patents

Description

The present invention relates to a flat yarn fabric used as a base material for sandbags, flexible container bags, weed control sheets, waterproof sheets, etc.

Many of the base materials such as sandbags, flexible container bags, weed control sheets, waterproof sheets such as blue sheets, construction sheets, and agricultural sheets are made by weaving yarns called flat yarns (hereinafter referred to as flat yarns). yarn fabric) is used. Flat yarn is obtained by cutting a film made of synthetic resin into pieces and stretching the film.

For example, sandbags made of flat yarn fabric are used when the bags are filled with soil, sand, etc., and the bags are piled up to construct embankments and waterproof walls. The length or height of the stack is arbitrary, but the stack may be several tens of meters long and several meters high.

Further, for example, a weed control sheet using flat yarn fabric is used to cover soil to block light and suppress the growth of weeds while maintaining water permeability. Waterproof sheets using flat yarn fabrics are made by laminating a resin coating layer on flat yarn fabrics such as Blue Sheet, and are used to prevent water from entering. When covering these sheets, the area often exceeds several ^tens of square meters.

These types of articles are often colored in a single color, such as the sandbags illustrated here in white or black, the weed control sheets in black, and the blue sheets in blue. If a vast area were to become one color, it would become a barren landscape that does not blend in with the landscape.

In order to blend in with the landscape, these bags and sheets should not be made entirely of a single color, but may be patterned with multiple colors. The pattern is not particularly regular, but is required to be irregular. Methods for forming such irregular patterns include printing on flat yarn fabrics, laminating printed films of flat yarn fabrics, or foam extrusion lamination on a base sheet as in Cited Document 1. A possible method is to provide a laminate layer containing at least one colored pigment, which is formed by forming defective portions.

Japanese Patent Application Publication No. 2001-293808

Bags and sheets made from the above-mentioned flat yarn fabrics are used outdoors and exposed over a wide range of areas, so in addition to having excellent physical properties such as resistance to pulling, tearing, and abrasion, they also have good weather resistance and are suitable for use as sandbags. Performance such as water permeability is also required for weed control sheets.

When a flat yarn fabric is printed to form an irregular pattern, the ink tends to come off because it is exposed to friction, and the ink does not have excellent weather resistance, which causes the problem that the color easily fades. Further, in waterproof sheets in which a resin coating layer is laminated on a textile, there is a problem in that the ink inhibits the adhesion between the resin coating layer and the flat yarn textile. When a printing film is attached to a flat yarn fabric, the problem of ink dripping due to friction is improved. However, the printed film impairs water permeability, making it difficult to use it for applications such as sandbags and weed control sheets. In addition, there was a problem in that it was difficult to firmly adhere the printed film and the flat yarn fabric. Furthermore, since a film that is hard enough to be printed on is used, there is a problem in that it is less flexible than a normal waterproof sheet.

When a laminate layer is provided on a base sheet using the foam extrusion lamination method as in Cited Document 1, water permeability can be ensured by having a defect, but since it is difficult to control the size of the defect, water permeability is There was a problem that unevenness was likely to occur. In addition, this defective portion creates unevenness in the thickness of the entire sheet, leading to the problem that it tends to cause unevenness in hardness and physical properties.

The present invention provides a flat yarn fabric that solves the above problems despite having an irregular pattern and can be used as a variety of base materials.

It is a woven fabric using flat yarns made of synthetic resin for the warp and weft, and at least one of the warp and weft is a multilayer flat yarn with different colors on the front and back sides, and the multilayer flat yarn has a soft twist. The above problem is solved by a flat yarn fabric in which an irregular pattern is formed on the fabric.

In the flat yarn fabric described above, the number of twists of the multilayer flat yarn is preferably 10 to 50 times/m. Further, in the above-mentioned flat yarn fabric, the multilayer flat yarn is preferably a uniform yarn made by aligning and overlapping at least two yarns of different colors. In the above-mentioned flat yarn fabric, the weaving density of the multilayer flat yarn is preferably 6 to 15 yarns/2.54 cm.

The flat yarn fabric of the present invention forms an irregular pattern due to the structure of the flat yarn fabric itself, and can be used as a variety of base materials.

1 is a photograph showing the appearance of an example of a flat yarn fabric.

The present invention is a fabric in which a flat yarn made of synthetic resin is used for the warp yarn and the weft yarn, and at least one of the warp yarn and the weft yarn is a multilayer flat yarn with different colors on the front and back sides, and the multilayer flat yarn is is a flat yarn fabric that is lightly twisted to form irregular patterns on the fabric. Hereinafter, preferred embodiments of this flat yarn fabric will be described.

Flat yarn fabrics are composed of synthetic resin. As the synthetic resin, thermoplastic resin can be suitably used. Examples of the thermoplastic resin include polyolefin, polyester, polyamide, polyvinyl alcohol, and the like. From the viewpoint of being used in a product that will ultimately be exposed over a wide range of uses, it is preferable that it is lightweight and inexpensive, and polyolefins can be suitably used. Examples of the polyolefin include high-density polyethylene, low-density polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, polypropylene, and the like. Among these, high-density polyethylene or polypropylene, which can be easily formed into a drawn thread and has excellent mechanical properties, is preferred. Whether polyethylene or polypropylene is used is selected in consideration of the characteristics depending on the application. Many flat yarn fabrics are used outdoors. For this reason, weather resistance and cold resistance are required, and flexibility is preferred for compact storage. Considering these points, it can be said that polyethylene is preferable, but in applications where performance such as heat resistance, hardness, and creep performance are important, it may be preferable to select polypropylene.

The method of forming the flat yarn is not particularly limited. The flat yarn can be obtained, for example, by melt-kneading a thermoplastic resin using an extruder, forming a film using a film forming machine, cooling and solidifying the film, and then performing slitting and stretching. In this case, the stretching treatment is preferably performed at a temperature below the melting point of the resin and above the softening point. As the heating method, for example, a hot roll method, a hot plate method, a hot air method, etc. can be adopted. The slit film may be stretched, for example, by utilizing the difference in circumferential speed between the front and rear rolls under heating. The stretching ratio is preferably 3 to 15 times, more preferably 5 to 10 times.

A flat yarn fabric is formed by using the flat yarn obtained as described above for warp yarns and weft yarns. The weave structure is not particularly limited, and plain weave, twill weave, satin weave, etc. can be employed. Many of the above flat yarn fabrics are used outdoors and are often required to be durable. For this reason, a plain weave that has high strength and is resistant to misalignment is preferred.

In flat yarn fabrics, at least one of the warp yarns and the weft yarns uses multilayer flat yarns that have different colors on the front and back sides. Multilayer flat yarns also include flat yarns in which multiple layers are bonded and integrated by coextruding two or more layers when forming a film, and multilayer flat yarns obtained from a single layer film are also included. It also includes flat yarns that are made into multiple layers by aligning and stacking them. In the multilayer flat yarn of the present invention, it is important that at least the front and back sides of the yarn are colored differently. That is, in the method of aligning and overlapping a plurality of flat yarns, the two flat yarns arranged on the front and back sides are selected to be colored in different colors. In addition, it is preferable that the coloring of the flat yarn is done by coloring by kneading a coloring agent together with a thermoplastic resin during melt-kneading in an extruder, and the coloring is particularly resistant to fading.

The fineness of the flat yarn used for the warp and weft yarns, including the multilayer flat yarn, is selected as appropriate, but is preferably in the range of 200 to 3500 dtex. In particular, multilayer flat yarns tend to become thinner when twisted, as described below. If the threads become too thin, the irregular patterns that will be formed in the flat yarn fabric may become less distinct. It is preferable that the yarn has a certain degree of fineness in advance, and from the viewpoint of minimizing the portion where the yarn becomes thinner due to twisting, the fineness of the multilayer flat yarn is preferably in the range of 500 to 3500 dtex.

The multilayer flat yarn is twisted. By subjecting multilayer flat yarns with different colors on the front and back sides to a gentle twisting process with a relatively small number of twists, twists occur at irregular positions, resulting in a state in which the colors on the front and back sides appear alternately, and when woven together, multiple The fabric has an irregular pattern with mottled colors.

The number of twists in the gentle twisting process applied to the multilayer flat yarn is preferably 10 to 50 twists/m. With such a number of twists, the intervals between the colors on the front and back sides will be appropriate, preventing the color assimilation effect and making it easier to obtain an irregular pattern. The color assimilation effect is a phenomenon in which adjacent colors appear to be in sync. If the number of twists is too large, there is a risk that the color will look like a mixture of the colors on the front and back sides of the multilayer flat yarn. In order to prevent the pattern from becoming difficult to recognize, it is preferable to use the above number of twists. Moreover, by setting the number of twists in this manner, when the flat yarn fabric is used for a sandbag, it is possible to prevent the sand filled inside from leaking out. Furthermore, when a flat yarn fabric is used for a weed control sheet, it is possible to prevent light from leaking. Furthermore, when a flat yarn fabric is used for a waterproof sheet, it is possible to prevent holes from forming in the sheet.

Multilayer flat yarn is twisted to make the colors on the front and back appear alternately to form an irregular pattern, so the colors on the front and back of multilayer flat yarn are brightness, saturation, and hue (these are called the three attributes of color). It is preferable that the values are far apart from each other. If the three color attributes are similar, the difference in color will be ambiguous, and even if the fabric is twisted and woven, the pattern that appears will be unclear. Most of the products will be used outdoors, and from the perspective of creating a pattern that takes into account the landscape, choosing colors such as green, which is similar to plants, or beige, which is similar to earth, will help it blend in with the surroundings.

The coloring agent used for coloring the multilayer flat yarn is preferably a pigment, and preferably one that can withstand the heat applied when kneading the synthetic resin. For example, phthalocyanine blue, phthalocyanine green, perylene red, perylene violet, perylene black, condensed azo red, condensed azo yellow, anthraquinone red, quinacudrine red, isoindolinone yellow, pyrazolone orange, diketopyrrolopyrrole red, dioxazine violet, One or more pigments selected from the group consisting of cobalt green, cobalt blue, titanium white, titanium yellow, yellow iron oxide, zinc oxide, barium sulfate, red iron oxide, aluminum powder, carbon black, black iron oxide, and composite fired pigments. can.

In order to make the mottled pattern that occurs in the flat yarn fabric more distinct, it is preferable to form the multilayer flat yarn into at least two or more aligned threads. Flat yarn is subjected to a gentle twisting process, and during this process it is easy to apply force that twists the yarn in one direction. If the layers of multilayer flat yarn are bonded together, they will tend to fold along the length of the yarn when twisted, which not only makes the yarn thinner, but also makes it difficult for one color to be exposed. be. This is thought to be due to the fact that the flat yarn is easily broken in the longitudinal direction due to uniaxial stretching. However, if two or more threads are drawn together, they are less susceptible to thread breakage, making it difficult for the threads to fold during twisting, and increasing the number of tape-like parts. . Furthermore, when two or more threads are drawn together, the tension of each thread is uneven, making the repetition of front and back sides more irregular. As a result, each unit of the mottled pattern becomes larger and the pattern appears more clearly.

Furthermore, in order to make the yarn less prone to folding during the gentle twisting process, it is necessary to create a multi-layer flat yarn made by pulling two or more flat yarns that have been folded in the longitudinal direction of the yarn and stacking them together. It is desirable to do so. In this case, since it is necessary to make the tape wide and thin in advance, the individual flat yarns forming the aligned yarns are likely to break. However, the yarn width will not become extremely thin because the part where the thread splits will be determined at the folded point, and the entire thread will not be covered by one of the threads that make up the thread. It almost disappears.

In flat yarn fabrics, it is preferable that mottled patterns appear at appropriate intervals. This makes the pattern easier to recognize. If the pattern becomes too fine, the pattern may become difficult to recognize due to the color assimilation effect described above. From this point of view, it is preferable to use a twisted yarn of multilayer flat yarn for only one of the warp yarn and the weft yarn. The other yarn in this case, which is to be interwoven with the multilayer flat yarn, is a plain weave, and if it is colorless or colored in a single color, the pattern formed by the strands of the multilayer flat yarn will be The color is not particularly limited since it does not become invisible. However, if this is not the case, the interweaving yarns may cause an assimilation effect and the color of the multilayer flat yarn may also appear changed. Therefore, in order to make the color of the multilayer flat yarn more clearly visible, it is preferable that the interweaving yarn is composed of uncolored or single-colored yarn, and more preferably, uncolored yarn is used.

The weaving density of the flat yarn fabric is preferably in the range of 5 to 24 yarns/2.54 cm for both warp yarns and weft yarns. Although the weaving density of the multilayer flat yarn may also be within this range, it is more preferable that the weaving density of the multilayer flat yarn is 6 to 15 yarns/2.54 cm. When the weaving density of the multilayer flat yarn is less than 6 threads/2.54 cm, the multilayer flat yarn tends to become thinner due to twisting, so that gaps and mesh misalignment are likely to occur. If the weave density exceeds 15 threads/2.54 cm, each thread exposed on the surface of the fabric will appear thinner, which will likely cause an assimilation effect, and the pattern may not be clearly visible. In addition, if a multilayer flat yarn made of aligned threads is used, it will be easier to maintain the spread state like a tape, which will be advantageous against gaps and misalignment, and will also be advantageous against pulling, tearing, rubbing, etc. Therefore, there is no need to forcibly increase the weave density.

The flat yarn fabric may contain weathering stabilizers, antioxidants, ultraviolet absorbers, lubricants, antistatic agents, inorganic fillers, flame retardants, crosslinking agents, blowing agents, nucleating agents, etc., within the scope of the invention. It is possible to mix and use the following additives.

Flat yarn fabrics have an irregular pattern that blends easily into the surrounding landscape, and can be used for weed control sheets, agricultural sheets, etc. By sewing flat yarn fabrics, it can also be used to make sandbags, flexible container bags, etc. Furthermore, by laminating a resin coating layer on the flat yarn fabric, waterproof properties can be imparted, so it can be used for construction sheets and various waterproof sheets.

When the flat yarn fabric is made of high-density polyethylene, it is preferable to use low-density polyethylene for the resin coating layer to be laminated when processing the flat yarn fabric into a waterproof sheet etc., considering the adhesion between the layers, and the extrusion lamination method is used. They may be laminated by a known method such as. In this case, if the resin coating layer is uncolored, the pattern of the flat yarn fabric will be visible as is, but even if the resin coating layer is colored, the pattern itself will be visible because the brightness of the base is reflected. It turns out.

High-density polyethylene (MFR = 0.8 g/10 min., density = 0.95 g/cm ³ , Tm = 131°C) and a commercially available hindered amine light stabilizer are mixed, the mixture is kneaded in an extruder, and T A film was created using a die method. After slitting the film into narrow widths, the film was stretched at a stretching ratio of 7 to create flat yarn A having a width of 5 mm and a fineness of 850 dtex.

Flat yarn B was prepared in the same manner as flat yarn A except that a green pigment was added to the above mixture.

Flat Yarn C was prepared in the same manner as Flat Yarn A except that a beige pigment was added to the above mixture.

The flat yarn B and the flat yarn C were arranged in pairs and twisted at a rate of 30 times/m to obtain a lightly twisted multilayer flat yarn.

Using the multilayer flat yarn as the weft yarn and flat yarn A as the warp yarn, plain weaving was carried out at a weaving density of 10×12 yarns/2.54 cm to obtain a flat yarn fabric. The appearance of the obtained flat yarn fabric is shown in Figure 1.

As shown in FIG. 1, the obtained flat yarn fabric had a pattern in which beige and green colors were irregularly arranged in a mottled manner.

[Sandbags]
The flat yarn fabric obtained as described above was processed into sandbags measuring 48 cm x 62 cm. Ten of the resulting sandbags filled with soil were arranged horizontally near the green zone, and next to them were ten commercially available sandbags (Super Sandbags manufactured by Hagiwara Kogyo Co., Ltd.) filled with soil. . In the areas where commercially available sandbags were used, the white color of the sandbags stood out against the surrounding green space, but in the areas where the sandbags of the present invention were used, they blended in with the surrounding landscape. In terms of practicality, the sandbags using the sandbags of the present invention were comparable in workability and durability to sandbags using commercially available sandbags.

[Tarpaulin sheet]
Low-density polyethylene (MFR = 5 g/10 min., density = 0.922 g/cm ³ , melting point = 121°C) was laminated on both sides of the flat yarn fabric obtained as above using an extrusion lamination method to form a waterproof sheet. processed. When the obtained tarpaulin sheet was used as an open pile cover, it blended in with the surrounding landscape. Normally, the sheets tend to tear due to rubbing against piled wood. No tearing occurred in the waterproof sheet using the flat yarn fabric of this example. Further, the waterproof sheet using the flat yarn fabric of this example had good flexibility and was easy to handle.

Claims (3)

It is a woven fabric that uses flat yarn obtained by cutting and stretching a film made of synthetic resin for the warp and weft yarns,
At least one of the warp yarn and the weft yarn is a multilayer flat yarn with different colors on the front and back sides,
Because the multilayer flat yarn is lightly twisted, twists occur at irregular positions in the multilayer flat yarn, and by alternating the colors on the front and back sides of the multilayer flat yarn, irregularities are created in the fabric. A pattern is formed,
The fineness of the multilayer flat yarn is 200 to 3500 dtex,
The weaving density of the multilayer flat yarn is 6 to 15 yarns/2.54 cm,
Flat yarn fabric for the base material of sandbags, flexible container bags, weed control sheets or tarpaulins. The flat yarn fabric according to claim 1, wherein the number of twists of the multilayer flat yarn is 10 to 50 twists/m. 3. The flat yarn fabric according to claim 1, wherein the multilayer flat yarn is a regular yarn made by aligning and overlapping at least two yarns of different colors.