JP7796493B2 - Yarn and fabric formed using said yarn - Google Patents

Description

The present invention relates to technology for yarns and fabrics formed using such yarns.

Yarn technology for producing fabrics with strong resilience has been publicly known, as described, for example, in Patent Document 1.

Patent Document 1 discloses a composite twisted yarn made by twisting together three types of yarn: spun yarn, polyurethane elastic yarn, and water-soluble yarn. When this composite twisted yarn is used to form a fabric (woven or knitted fabric), removing the water-soluble yarn from the woven or knitted fabric makes it possible to obtain a woven or knitted fabric with strong resilience.

Patent No. 4204498

Patent Document 1 mentions rebound force, but makes no mention of shock absorption.

The present invention was made in light of the above circumstances, and the problem it aims to solve is to provide yarn that exhibits excellent shock absorption properties when made into fabric, and fabric with excellent shock absorption properties.

The above is the problem that this invention aims to solve, and next we will explain the means for solving this problem.

That is, the thread according to the present invention comprises a material having impact absorption properties and a sheath thread having solubility or sublimability that covers the material so as to maintain the stretched state of the stretched material , and the material is in a gel state .
By configuring the fabric in this way, when the sheath yarn is removed from the fabric, the stretched state is released, allowing the fabric to exhibit excellent shock absorption. Also, by configuring the fabric in this way, the fabric can exhibit excellent shock absorption effectively.

The material may have a diameter of 0.1 mm to 8.0 mm when in its natural, non-stretched state.
By configuring it in this way, it is possible to effectively exhibit excellent shock absorption properties when made into a fabric.

The material may also have a diameter of 0.05 mm to 4.0 mm when in the stretched state.
By configuring it in this way, it is possible to effectively exhibit excellent shock absorption properties when made into a fabric.

The thread according to the present invention may have a diameter of 0.05 mm to 4.0 mm.
By configuring it in this way, it can be easily woven by a textile machine, and when made into a fabric, it can effectively exhibit excellent shock absorption properties.

The thread according to the present invention may have a diameter of 2.0 mm to 4.0 mm.
By configuring it in this way, it can be easily woven by a textile machine, and when made into a fabric, it can more effectively exhibit excellent shock absorption properties.

Furthermore, a fabric according to the present invention is a fabric formed using the yarn according to any one of claims 1 to 6.
By configuring in this way, it is possible to provide excellent shock absorption properties.

The fabric may be a knitted fabric, and the yarn may be used as a knitting yarn for knitting the knitted fabric.
By configuring in this way, it is possible to effectively achieve excellent shock absorption properties.

The fabric may be a knitted fabric, and the yarn may be used as an inlay yarn.
By configuring in this way, the knitted fabric having the inlay yarn can have excellent shock absorption properties.

The fabric may also be formed into a spacer fabric having a front knitted fabric and a back knitted fabric, and the yarn may be used as a connecting yarn that connects the front knitted fabric and the back knitted fabric.
By configuring it in this way, when the material in a stretched state changes to its natural state, the yarn can be made to stand up between the front knitted fabric and the back knitted fabric, and excellent shock absorption can be achieved between the front knitted fabric and the back knitted fabric.

The effect of the present invention is to provide yarn that exhibits excellent shock absorption properties when made into fabric, and fabric with excellent shock absorption properties.

1A is a schematic diagram showing a preparation step, a drawing step, and a restraint step of a yarn manufacturing process according to an embodiment of the present invention; (a) A schematic diagram showing the knitting process in the manufacturing process of a fabric using the yarn according to one embodiment of the present invention, (b) A schematic diagram showing the dissolving process in the same, and (c) A schematic diagram showing the shrinking and filling processes in the same. 10A is a schematic diagram showing a knitting step in a manufacturing process of a fabric according to another embodiment, and FIG. 10B is a schematic diagram showing a dissolving step and a shrinking and filling step in the same manufacturing process.

The yarn 10 according to one embodiment of the present invention, shown in Figure 1(c), is a yarn for forming (manufacturing) fabric. When made into fabric, the yarn 10 exhibits excellent shock absorption properties. Below, the yarn 10 and the manufacturing process for the yarn 10 will be described using Figure 1. The manufacturing process for the yarn 10 mainly includes a preparation process S11, a drawing process S12, and a restraining process S13.

The preparation step S11 shown in Figure 1(a) is a step of preparing material 11. Material 11 is a longitudinal (thread-like) low-resilience material that has extensibility and shock absorption properties. Here, shock absorption refers to the ability to absorb external shocks. In this embodiment, a gel-like material (gel-like material) with a predetermined viscosity and made primarily of polyurethane, silicone, etc. is used as the material for material 11.

The material for base 11 is not limited to the gel-like material described above, but may be any low-resilience material with extensibility and shock absorption properties, such as an impact-absorbing polymer. Furthermore, the material for base 11 may be one that changes shape slowly when subjected to low external pressure, dispersing the force received without concentrating it in a specific area.

The material 11 is formed to have a generally circular cross section. The diameter of the material 11 can be any size depending on the application. In this embodiment, the diameter of the material 11 is between 0.1 mm and 8.0 mm.

After the preparation step S11, the stretching step S12 is carried out.

The stretching process S12 shown in Figure 1(b) is a process in which the material 11 prepared in the preparation process S11 is stretched (extended) in the longitudinal direction. More specifically, the stretching process S12 is a process in which the material 11 is temporarily held in a stretched state in the longitudinal direction using a specified device. Note that, hereinafter, the state of the material 11 before stretching is referred to as the "natural state," and the state of the material 11 after stretching is referred to as the "extended state." As will be described later, the material 11 held in the stretched state has a smaller diameter than in the natural state because it has been stretched from its natural state.

The diameter of the material 11 held in a stretched state can be any size depending on the application. In this embodiment, the diameter of the material 11 held in a stretched state is between 0.05 mm and 4.0 mm. In this way, stress (a force trying to contract) against the stretching tension is constantly acting on the material 11 held in a stretched state.

After the stretching step S12, the restraining step S13 is carried out.

The restraining step S13 shown in Figure 1(c) is a step in which the material 11, which was held in an elongated state in the drawing step S12, is restrained in that elongated state (so that it remains held in that state even after being removed from the specified device). In the restraining step S13, two sheath yarns 12 of the same diameter and material are used. In this embodiment, the two sheath yarns 12 are soluble water-soluble vinylon (water-soluble yarn).

Specifically, in the restraining step S13, as shown in Figure 1(c), two sheath yarns 12 twisted in opposite directions are wound around the material 11, which is held in a stretched state by a specified device, in a spiral pattern in opposite directions toward one side of the longitudinal direction of the material 11. Note that Figure 1(c) is a conceptual diagram of the restraining step S13; in reality, the two sheath yarns 12 are wound tightly around the material 11, as shown in the partial view indicated by reference symbol A. By winding the two sheath yarns 12 around the material 11 in this way, the material 11, which was held in a stretched state in the drawing step S12, is restrained by the two sheath yarns 12 in its stretched state even when it is released from the hold by the specified device. In other words, the stretched state of the material 11 is maintained (maintained).

As a result, a single thread 10 (double covered yarn) is produced in which the stretched material 11 is covered with two sheath yarns 12, as shown by symbol A in Figure 1(c). As shown by symbol A, the two sheath yarns 12 are wound tightly together (so that adjacent portions of the material 11 are in close contact with each other in the longitudinal direction) so that the material 11 is not visible from the outside. In this way, the thread 10 is formed so that almost the entire material 11 is covered from the outside, and the material 11 is not exposed to the outside through the gaps between the coverings made by the two sheath yarns 12.

This increases the contact area between the material 11 and the sheath yarn 12, more reliably restraining the stretched state of the material 11. Furthermore, as described above, the viscous gel material (material 11) is not exposed to the outside, making the yarn 10 easier to handle (for example, it can be used in textile machines such as flat knitting machines, which will be described later). The diameter of the yarn 10 can be any size depending on the application. In this embodiment, the diameter of the yarn 10 is from 0.05 mm to 4.0 mm.

It is preferable that the sheath yarn 12 be made from spun staple fibers rather than from spun long fibers. That is, if the sheath yarn 12 is made from spun long fibers, it will tend to shrink longitudinally more easily than if it were made from spun short fibers, for example, if it absorbs moisture from the surrounding area. Therefore, if the sheath yarn 12 shrinks in an unintended manner, it could have an adverse effect (detriment) on the covering material 11. Therefore, by using sheath yarn 12 made from spun short fibers, the above-mentioned disadvantages can be reduced.

The following describes the fabric formed using yarn 10 and the manufacturing process for the fabric, using Figure 2. Note that the following description assumes that the fabric is a rib knit fabric 40 formed using yarn 10 as an inlay yarn. The manufacturing process for rib knit fabric 40 mainly includes a knitting process S21, a dissolving process S22, and a shrinking/filling process S23.

Knitting step S21 shown in Figure 2(a) is a step of knitting a rib knit fabric using yarn 10 as an inlay yarn. Hereinafter, the (pre-finished) rib knit fabric knitted in knitting step S21 will be referred to as rib knit fabric 30 to distinguish it from the (finished) rib knit fabric 40 after the shrinking/filling step S23. Figure 2(a) is a schematic cross-sectional view of the knitted rib knit fabric 30. For ease of explanation, Figure 2(a) illustrates the yarn 10 in a state where the material 11 is exposed (see Figure 1(c)). In other words, Figure 2(a) is a conceptual diagram of knitting step S21; in reality, the two sheath yarns 12 are wrapped tightly around each other, preventing the material 11 from being exposed to the outside (see the partial view indicated by symbol A in Figure 1(c)).

The rib knitted fabric 30 is knitted by a flat knitting machine. In the flat knitting machine, knitting yarn 41 is passed between the front and rear needle beds, and the rib knitted fabric 30 is knitted with the knitting yarn 41 to have knit stitches 42 and purl stitches 43. A shrinkable yarn is used as the knitting yarn 41. Specifically, the knitting yarn 41 is either a yarn in which an elastic yarn is pulled together, or an elastic yarn covered with a regular (general) knitting yarn.

The rib knit fabric 30 is knitted (inlaid) with yarn 10 acting as a weft yarn between the knit stitches 42 and purl stitches 43. The position of yarn 10 in the vertical direction (wale direction) of the rib knit fabric 30 is fixed by a floating yarn (knitting yarn 41) (not shown) that passes between the knit stitches 42 and purl stitches 43. By repeating this knitting process, a rib knit fabric 30 can be obtained in which yarn 10 (inlay yarn) is distributed throughout. It is also possible to use multiple yarns 10 (inlay yarns) rather than just one (single). This allows for a higher packing density.

After the knitting process S21 is performed, the dissolving process S22 is performed next.

The dissolving step shown in Figure 2(b) is a step in which the sheath yarn 12 of the yarn 10 is dissolved from the rib knitted fabric 30 (fabric) knitted in the knitting step S21. Specifically, the rib knitted fabric 30 is washed with a specified cleaning solution such as water to dissolve the sheath yarn 12 covering the material 11 of the yarn 10. In this way, the yarn 10 is made up of only the material 11. This releases the constraint of the stretched state of the yarn 10 (material 11).

After the dissolving process S22, the shrinking and filling process S23 is carried out.

The shrinking/filling process S23 shown in Figure 2(c) is a process in which, after dissolving the sheath yarn 12 of the yarn 10 in the dissolving process S22, the yarn 10 (material 11) is shrunk and the shrunk material 11 is filled into the rib knit fabric 30 (thickening the material 11). Specifically, when the sheath yarn 12 of the yarn 10 is dissolved in the dissolving process S22 as described above, the constraint of the stretched state of the material 11 is released. As a result, the material 11 naturally shrinks in the longitudinal direction due to the elastic force of the material 11 itself, transitioning from the stretched state to its natural state. Furthermore, as described above, a shrinkable yarn is used for the knitting yarn 41 of the rib knit fabric 30. In this way, in the shrinking/filling process S23, the material 11 and knitting yarn 41 of the rib knit fabric 30 both shrink, resulting in the formation of a rib knit fabric 40 that is wider in the thickness direction of the fabric than the rib knit fabric 30.

As a result, compared to the state before the shrinking/filling process S23 (i.e., the state of the rib knitted fabric 30), the rib knitted fabric 40 has a larger diameter yarn 10 (i.e., material 11 in its natural state with shock absorption properties) arranged throughout the knitted fabric. In other words, when the yarn 10 (material 11) is made into the rib knitted fabric 40, it is able to exhibit excellent shock absorption properties. Furthermore, the rib knitted fabric 40 with the inlay yarn (material 11) becomes a knitted fabric that essentially contains cushioning material, and is able to have excellent shock absorption properties.

In addition, in this embodiment, material 11 is a gel-like material with relatively high shock absorption properties. That is, the rib knit fabric 40 according to this embodiment uses the gel-like material (material 11) as a cushioning material, and therefore effectively possesses excellent shock absorption properties. Furthermore, gel-like materials generally have a relatively high viscosity, making them unsuitable as materials for manufacturing fabrics using textile machines (e.g., knitting machines, looms, etc.). However, in this embodiment, material 11 (gel-like material) is almost entirely covered from the outside by two sheath yarns 12 and manufactured as yarn 10. In this way, material 11 (gel-like material) can be used as a material for manufacturing fabrics using textile machines, regardless of its viscosity.

General textile machines have an upper limit on the diameter of the yarn used. For example, in general flat knitting machines, the distance between the needle beds is typically 5.0 mm or less. In contrast, in this embodiment, the diameter of the yarn 10 is 0.05 mm to 4.0 mm. That is, even if the diameter of the material 11 in its natural state is larger than the distance between the needle beds (i.e., the material 11 cannot be used in the flat knitting machine with its original diameter), the diameter is reduced when the fabric is produced, so it can be used in the flat knitting machine. This makes it easier to knit and weave with a textile machine, and allows for a wider range of material choices, allowing for the selection of yarn 10 that is suitable for producing fabric, and ultimately resulting in fabric that effectively exhibits excellent shock absorption properties.

In addition, in this embodiment, the diameter of the material 11 held in a stretched state (the diameter of the material 11 covered with the sheath yarn 12) is selected from the range of 0.05 mm to 4.0 mm. In other words, when manufacturing fabric, a material 11 of an appropriate size can be used, excluding materials that are excessively small or large for use in the fabric. This allows fabric to be manufactured from a material with relatively high shock absorption properties and an appropriate diameter for the material 11 held in a stretched state. In other words, when made into fabric, excellent shock absorption properties can be effectively achieved.

In addition, in this embodiment, the diameter of the material 11 in its natural state is selected to be between 0.1 mm and 8.0 mm. In other words, when manufacturing fabric, a material 11 of an appropriate size can be used, excluding materials that are excessively small or large. This allows fabric to be manufactured using a material with a suitable diameter for the material 11 in its natural state and relatively high shock absorption. In other words, when made into fabric, excellent shock absorption can be effectively achieved.

In addition, in this embodiment, the sheath thread 12 constrains the fibers, which have a diameter of 0.1 mm to 8.0 mm in their natural state, to a diameter of 0.05 mm to 4.0 mm in their stretched state, eliminating fibers that undergo excessive change between their natural and stretched states. This allows fabric to be manufactured from a material with relatively high shock absorption properties that exhibits favorable change between their natural and stretched states. In other words, when made into fabric, the material effectively exhibits excellent shock absorption properties.

The above describes an embodiment of the present invention, but the present invention is not limited to the above embodiment and can be modified as appropriate within the scope of the technical concept of the invention described in the claims.

For example, in this embodiment, the sheath yarn 12 is water-soluble vinylon (water-soluble yarn), but this is not limited to this. That is, for example, the sheath yarn 12 may be a sublimation yarn that sublimes when heated, rather than a soluble yarn. This can prevent the sheath yarn 12 from absorbing moisture from the surrounding area. In this way, any material that can be removed by a predetermined method after the fabric has been manufactured can be used as the sheath yarn 12.

In this embodiment, the yarn 10 is a double-covered yarn in which two sheath yarns 12 are wound around the material 11 (core yarn), but this is not limited to this. For example, the yarn 10 can also be a single-covered yarn in which one sheath yarn 12 is wound around the material 11 (core yarn). The yarn 10 can also be one in which three or more sheath yarns 12 are wound around it. Furthermore, the yarn 10 may have the material 11 exposed to the outside between the coverings of the sheath yarn 12.

In addition, in this embodiment, knitted fabric was produced as the fabric, but this is not limited to this. In other words, woven fabric may also be produced as the fabric. Furthermore, a flat knitting machine was used as the textile machine for producing the fabric, but this is not limited to this. In other words, warp knitting machines and circular knitting machines can be used as textile machines for knitted fabrics, and looms can be used for woven fabrics. In this way, any textile machine can be used depending on the type of fabric to be produced.

In addition, in this embodiment, yarn 10 is used as an inlay yarn, but this is not limited to this. That is, yarn 10 can also be used as a knitting yarn to create a knitted fabric. In this way, when a knitted fabric is knitted using only yarn 10, the gaps in the knitted fabric can function as relief areas in the event of external pressure. In this way, when a knitted fabric is knitted using only yarn 10, the impact absorption can be increased by the amount of the gaps in the knitted fabric compared to, for example, a plate-shaped member made of a single material that has impact absorption properties. Furthermore, when knitting a fabric using yarn 10, it is possible to knit any type of knitted fabric, not just a rib knitted fabric as in this embodiment.

In addition, in this embodiment, the rib knit fabric 40 was produced using the yarn 10 as an inlay yarn, but this is not limited to this. In other words, any knit fabric other than a rib knit fabric can be knitted using the yarn 10 as an inlay yarn. For example, after knitting plain knitting (plain stitch) on one of the front and rear needle beds on a flat knitting machine, the yarn 10 (inlay yarn) can be passed through the knit fabric by transferring a predetermined (e.g., even-numbered) stitch to the other front or rear needle bed and setting it in the same way as the rib knit fabric.

Below, using Figure 3, we will explain another embodiment of a spacer fabric-like fabric formed using yarn 10, as well as the manufacturing process for the fabric.

The fabric shown in Figure 3(b) is a spacer fabric-like fabric (hereinafter referred to as "spacer fabric 140" for convenience) formed using yarn 10. Note that hereinafter, the spacer fabric-like fabric knitted in knitting step S121 (before completion) will be referred to as spacer fabric 130 to distinguish it from spacer fabric 140 (after completion) after shrinking/filling step S23 has been performed.

In the knitting step S121 shown in Figure 3(a), the spacer fabric 130 is knitted on a flat knitting machine. The spacer fabric 130 has a knitted fabric portion 141 knitted with a highly elastic yarn such as rubber yarn, and a tuck portion 142 made of yarn 10. A pair of knitted fabric portions 141 (front knitted fabric and back knitted fabric) are provided, spaced apart and facing each other. The tuck portion 142 (yarn 10) connects the pair of knitted fabric portions 141 (front knitted fabric and back knitted fabric). In other words, yarn 10 is used as a connecting yarn that connects the pair of knitted fabric portions 141. The tuck portion 142 (yarn 10) is knitted in a zigzag pattern between the pair of knitted fabric portions 141.

In the dissolving process S122 shown in Figure 3(b), the sheath yarn 12 of the yarn 10 is dissolved in the tuck section 142. That is, the yarn 10 (material 11) is released from its stretched state in the tuck section 142. Then, in the shrinking/filling process S123, the high-elasticity yarn causes each of the pair of knitted fabric sections 141 to shrink in the width direction of the fabric, and the yarn 10 (material 11), which has been released from its stretched state in the tuck section 142, increases in diameter and shrinks in the longitudinal direction. That is, as the tuck section 142 transitions to stand up between the pair of knitted fabric sections 141, the shape of the fabric (spacer fabric 130) itself changes so as to move the pair of knitted fabric sections 141 away from each other. In this way, a spacer fabric 140 is formed that is wider in the thickness direction of the fabric than the spacer fabric 130.

In the spacer fabric 140 formed in this manner, the pair of knitted fabric portions 141 are spaced apart from each other, providing cushioning in the thickness direction of the fabric. Furthermore, the portion connecting the pair of knitted fabric portions 141 (tuck portion 142) is formed from material 11 in its natural state, which has shock-absorbing properties, allowing the spacer fabric 140 as a whole to have excellent shock-absorbing properties.

In the spacer fabric 140, the pair of knitted fabric portions 141 may not be knitted with highly elastic yarn, but may instead be knitted using yarn 10, as in the rib knitted fabric 40. This allows the spacer fabric 140 as a whole to have even better shock absorption properties.

The diameter of the thread 10 is not limited to the above-mentioned range of 0.05 mm to 4.0 mm, and preferably can be 2.0 mm to 4.0 mm. Here, when using a thread 10 with a relatively small diameter, such as 0.05 mm, it is expected that multiple threads will be used together rather than one at a time. In such cases, handling can become cumbersome, for example, when using the thread 10 as an inlay thread or when using the thread 10 to form a spacer fabric 140, as described above.

However, if the yarn 10 has a relatively large diameter, such as 2.0 mm to 4.0 mm, it can be used alone. For example, if it is difficult to knit the yarn 10 as is on a flat knitting machine, the yarn 10 can be pulled to make it thinner (reduced in diameter) and easier to knit. Furthermore, by knitting it at a thinner diameter in this way, the impact-absorbing yarn 10, which is originally large in diameter, can be fixed at a thinner diameter on a flat knitting machine, circular knitting machine, or warp knitting machine, and can be knitted using knitting needles of the same size as regular yarns. Furthermore, on a general loom, the impact-absorbing yarn 10, which is originally large in diameter, can be woven without changing components such as the shuttle.

By setting the diameter of the thread 10 to 2.0 mm to 4.0 mm, it is possible to select the thread 10 that is most suitable for manufacturing fabric, and ultimately to more effectively demonstrate excellent shock absorption properties when made into fabric.

10 Yarn 11 Material 12 Sheath yarn 40 Rib knit fabric

Claims (9)

A material having shock absorption properties;
a soluble or sublimable sheath yarn covering the stretched material so as to maintain the stretched state of the material;
Equipped with
The material is in a gel state.
thread. The material has a diameter of 0.1 mm to 8.0 mm when in a natural, non-stretched state.
The yarn of claim 1. the material has a diameter of 0.05 mm to 4.0 mm when in the stretched state;
The yarn of claim 2. The diameter of the thread is 0.05 mm to 4.0 mm.
The yarn according to any one of claims 1 to 3. The diameter of the thread is 2.0 mm to 4.0 mm.
The yarn of claim 4. A fabric formed using the yarn according to any one of claims 1 to 5. The fabric is a knitted fabric,
The yarn is used as a knitting yarn for knitting a knitted fabric.
The fabric according to claim 6 . The fabric is a knitted fabric,
The yarn is used as an inlay yarn.
The fabric according to claim 6 or claim 7. The fabric is formed into a spacer fabric having a front knitted fabric and a back knitted fabric,
The yarn is used as a connecting yarn that connects the front knitted fabric and the back knitted fabric.
The fabric according to any one of claims 6 to 8 .