JP7849865B2 - Three-dimensional structural material - Google Patents

Description

This invention relates to a three-dimensional structural material having voids that are easily deformable and possess morphological stability.

Three-dimensional structural materials have been proposed that provide cushioning properties through voids formed in sheet materials such as fabrics. For example, Patent Document 1 describes a three-dimensional structural fabric in which high-shrinkage yarns are woven into the single-layer weave sections of the upper and lower ground fabrics, and then used as floating yarns in the double-layer weave section, thereby shrinking the high-shrinkage yarns and forming the double-layer weave section into a continuous tubular shape.

Furthermore, three-dimensional structural materials have been proposed in which cushioning material is inserted into voids formed in a sheet material to provide cushioning. For example, Patent Document 2 describes a mattress in which two pieces of fabric are overlapped and sewn together at a predetermined interval to form an insertion tube, and a tubular mesh-like body with cushioning properties is inserted into the formed insertion tube. Patent Document 3 describes a back cushion in which a cushion pad is housed in a sleeve of an outer body sewn using fabric to provide cushioning.

Japanese Patent Application Publication No. 8-226044 Japanese Patent Publication No. 2016-83247 Japanese Patent Publication No. 2018-191758

In Patent Document 1, the upper and lower ground layers are used to form a continuous cylindrical shape, creating a void to provide cushioning. However, in the cylindrical portion, when pressed in a direction perpendicular to the axis, the curved threads tend to collapse sideways, posing a problem in terms of cushioning.

As described in Patent Documents 2 and 3, when cushioning material such as a cushion pad is inserted into an insertion part formed in fabric, the cushioning effect is enhanced, but the resulting material becomes harder than the flexibility of the fabric. Therefore, it is not suitable for applications requiring flexibility, and thus has drawbacks in terms of versatility.

Therefore, the present invention aims to provide a three-dimensional structural material that enhances the morphological stability of voids while maintaining the flexibility of the fabric.

The three-dimensional structural material according to the present invention comprises a hollow cylindrical body that expands and contracts in the axial direction and in a direction perpendicular to the axis, and has shape recovery properties , a void formed inside the cylindrical body , and a base part made of fabric with a bag-like part that encloses the cylindrical body, wherein the cylindrical body is a braided body woven into a cylindrical shape using linear material that has shape recovery properties.
Another three-dimensional structural material according to the present invention comprises a hollow cylindrical body that expands and contracts in the axial direction and in a direction perpendicular to the axis , and has shape-restoring properties; a void formed inside the cylindrical body ; and a base part made of fabric in which a bag-like part is formed that houses the cylindrical body. Multiple voids are formed by housing the cylindrical bodies in each of the bag-like parts which are formed in parallel .

The present invention, with its above-described configuration, forms a void using a tubular body that expands and contracts axially and perpendicularly to the axis, while also possessing shape-recovering properties. This allows for increased dimensional stability of the void while maintaining the flexibility of the fabric, and also reduces weight, resulting in a highly versatile three-dimensional structural material.

This is a perspective view relating to a three-dimensional structural material according to the present invention. This is a cross-sectional view taken along line A-A in Figure 1. This is an explanatory diagram illustrating the case when a stretchable bag-like portion is pressed and deformed. This is a perspective view relating to a modified example of the embodiment shown in Figure 1. Figures 1 and 1 show a perspective view and a plan view relating to another modified example of the embodiment shown in Figure 1. This is a perspective view of a cylindrical body and a perspective view showing the cylindrical body stretched in the axial direction.

The embodiments of the present invention will be described in detail below. While the embodiments described below are preferred examples for carrying out the present invention and therefore have various technical limitations, the present invention is not limited to these forms unless specifically stated in the following description to limit the invention.

Figure 1 is a perspective view relating to a three-dimensional structural material according to the present invention, and Figure 2 is a cross-sectional view taken along line A-A in Figure 1. The three-dimensional structural material 1 has a base portion 2 made of fabric with a bag-shaped portion 3 formed thereon. A cylindrical body 4 is embedded in the bag-shaped portion 3, forming a void portion 5. In this example, the three-dimensional structural material 1 is formed in a strip shape by connecting the bag-shaped portions 3 to each other, and the multiple void portions 5 formed within the bag-shaped portions 3 are arranged in parallel in a cylindrical configuration.

The hollow cylindrical body 4 that forms the void 5 expands and contracts axially and perpendicular to the axis, while also possessing shape-recovering properties. Because the cylindrical body 4 has the characteristic of expanding and contracting perpendicular to the axis to restore its shape, when it is housed within the bag-like portion 3, it acts to expand the bag-like portion 3, thereby forming the void 5.

Furthermore, if the bag-like portion 3 is made of an elastic fabric, the cylindrical body 4 will expand and contract in accordance with the expansion and contraction of the bag-like portion 3, thus providing shape stability even with respect to the expansion and contraction deformation of the base portion 2.

Figure 3 is an explanatory diagram illustrating the case when the stretchable bag-shaped portion 3 is pressed and deformed. In this example, the bag-shaped portion 3 is made of a stretchable fabric due to woven or knitted elastic threads, and a tubular body 4 is built into the bag-shaped portion 3, forming a void portion 5.

When an external pressure F is applied to the bag-shaped portion 3, the cylindrical body 4 contained within the bag-shaped portion 3 is compressed in the width direction and attempts to stretch axially (Figure 3(a)). However, the bag-shaped portion 3 attempts to contract by being pulled into the pressure area due to the action of the elastic threads (Figure 3(b)). Therefore, the cylindrical body 4 is dragged along by the contracting action of the bag-shaped portion 3 and deforms in a direction that expands in diameter at the pressure area, pushing and expanding the bag-shaped portion 3, thus generating a repulsive force G against the pressure F (Figure 3(c)). By increasing this repulsive force, the cushioning properties can be improved.

When the base portion 2 undergoes deformation such as compression or bending, it deforms accordingly, and the void portion 5 acts to restore its original shape. Therefore, the three-dimensional structural material 1 can be easily deformed to conform to the shape of the product to which it is attached, providing versatility for attachment to various parts of products.

Due to the shape-restoring properties of these voids 5, the three-dimensional structural material 1 can possess cushioning properties. Furthermore, because the voids 5 maintain a connected state, a connected state is created through which wires such as wiring and optical fibers can be inserted. This allows the wires to be protected by the cylindrical body and held in a stable state without being subjected to load.

Figure 4 is a perspective view of a modified embodiment of the one shown in Figure 1. In this example, the base portion 2 has connecting portions 6 of a predetermined width extending from both sides of the connected bag-shaped portion 3. The connecting portions 6 can be used as seam allowances, allowing the three-dimensional structural material 1 to be easily sewn onto various products.

Figure 5 shows a perspective view (Figure 5(a)) and a plan view (Figure 5(b)) of another modified example of the embodiment shown in Figure 1. In this example, fastening portions 7 that partially seal or narrow the bag-shaped portion 3 are provided at predetermined intervals. Therefore, the void portion 5 is divided into multiple partitioned void portions 5a by the fastening portions 7 at predetermined lengths. Since the internal cylindrical body 4 is fastened in the fastening portions 7 so that it does not partially shift in the axial direction, the repulsive force against compressive or bending deformation of the cylindrical body 4 is increased in the partitioned void portions 5a, making it possible to improve cushioning.

Furthermore, since the tubular body 4 expands and contracts axially and perpendicular to the axis, it deforms into a thin, linear shape when stretched by applying tensile force along the axial direction. Therefore, when weaving or knitting the base portion 2, by weaving or knitting the tubular body 4 as an insert yarn into the structure forming the bag-shaped portion 3, it becomes possible to weave or knit the base portion 2 integrally while embedding the tubular body 4 within the bag-shaped portion 3, enabling efficient production of three-dimensional structural materials. Additionally, the tubular body 4 can be inserted into and attached to the bag-shaped portion 3 in its thin, linear shape, and removed, allowing for easy attachment and detachment of the tubular body 4 to the base portion 2 as needed, facilitating maintenance and other processes.

The three-dimensional structural material 1 can be formed into shapes other than a strip. For example, a fabric with multiple voids 5 can be formed into a sheet, tube, or bag to constitute the base portion 2, and is not particularly limited. Furthermore, the bag-shaped portion 3 of the base portion 2 can be arranged in various layouts and is not particularly limited. As described above, when arranging the voids 5 in parallel, at predetermined intervals, or in only a portion of the base portion 2, the bag-shaped portion 3 can be formed according to the layout of the voids 5.

As a three-dimensional structural material 1, it is possible to form a pipe-like structure with a single interconnected void 5 by forming a base portion 2 so as to cover a single cylindrical body 4, allowing for various shapes to be constructed according to the application. Furthermore, it is also possible to create a three-dimensional structural material by laminating multiple void portions 5 in multiple layers.

The bag-like portion 3 formed on the base portion 2 can be formed in a continuous state, as shown in Figure 1, or partially sealed or narrowed, as shown in Figure 5, allowing the void portion 5 to be set to a continuous or partitioned state according to the application. In this case, the bag-like portion 3 can be partially sealed or narrowed by methods such as weaving, knitting, or sewing, and can also be formed by partial bonding using known means such as press heating or ultrasonic heating.

The base portion 2 is preferably made of a fabric woven or knitted from yarn made of a fibrous material. The fibrous material used for the yarn can be any known material and is not particularly limited. Examples of synthetic fibrous materials include polyester, nylon, acrylic, polypropylene, para-aramid, meta-aramid, polyarylate, and polybenzimidazole. Examples of natural fibrous materials include cotton, wool, and linen. Examples of inorganic fibrous materials include glass. Furthermore, a mixture of these fibrous materials may also be used.

Monofilament or multifilament yarns made from such synthetic or natural fiber materials are preferred. When using elastic yarns to impart stretchability, elastic yarns made from elastic materials such as polyurethane, synthetic rubber, natural rubber, or silicone are preferred.

The yarn, made from synthetic or natural fiber materials, is not particularly limited in fineness, but fineness between 30 decitex and 1200 decitex is preferred.

For elastic yarns, if polyurethane is used, a fineness of 13 to 2500 decitex is preferred, and more preferably 22 to 1240 decitex. If synthetic rubber, natural rubber, or silicone is used, a single-fiber diameter of 0.3 mm to 1.5 mm is preferred, and more preferably 0.4 mm to 1.3 mm.

Furthermore, while monofilament yarn, multifilament yarn, or spun yarn can be used as the yarn, filament yarn is preferred. The yarn should be twisted 10 to 300 times per meter to prevent the constituent fiber material from unraveling.

The bag-shaped portion 3 formed on the base portion 2 can be integrally formed by known weaving methods such as tubular weaving or tubular knitting, or by known knitting methods such as tubular knitting or tubular knitting. Alternatively, it can be formed by sewing multiple layers of fabric together at predetermined intervals, or by placing a strip of fabric on the surface of the base and sewing both ends of the fabric together to form a bag.

As the tubular body 4, a braided cord woven into a tubular shape using linear material with shape-recovering properties is preferred. By using such a braided cord for the tubular body 4, tubular bodies of various weights and sizes can be obtained by changing the weaving density of the linear material, thereby obtaining three-dimensional structural materials that can be finely adapted to various applications.

Figure 6 shows a perspective view of the cylindrical body 4 (Figure 6(a)) and a perspective view of the cylindrical body 4 under axial tension (Figure 6(b)). Because this braided body is formed by weaving multiple linear materials spirally into a cylindrical shape, it expands and contracts axially, expanding and contracting in directions perpendicular to the axis. Furthermore, because the linear materials possess shape-recovering properties, the braided body returns to its original cylindrical shape even after compression or bending deformation, resulting in a lightweight and shape-stable structure.

Furthermore, by pulling the braided cord in the axial direction, it stretches axially and deforms into a long, slender cord, making it usable as an insert thread during the weaving or knitting of the base part 2. Then, after the weaving or knitting of the base part 2, the braided cord expands in diameter to return to its original shape, creating a void.

When manufacturing the three-dimensional structural material illustrated in Figure 4, when weaving or knitting the base portion 2 while it is stretched into a long, narrow cord shape, the fastening portion 7 is formed so that it narrows to both sides of the deformed cord. This ensures that after manufacturing, the portion of the cord narrowed at the fastening portion 7 does not expand in diameter, while the rest of the cord expands to return to its original shape, forming a partitioned void portion 5a.

Preferred linear materials with shape-recovery properties for use in braided structures include monofilament or multifilament yarns made from synthetic fiber materials such as polyester, nylon, and polypropylene, as well as linear materials made from metallic materials such as shape memory alloys and superelastic alloys.

Furthermore, in the case of monofilament or multifilament yarns made from synthetic fiber materials, the single yarn diameter is preferably 0.05 mm to 1.0 mm, and more preferably 0.1 mm to 0.5 mm.

The braided cord is preferably formed with a diameter of 3 mm to 30 mm, more preferably 5 mm to 20 mm. When weaving the braided cord, the number of bends is preferably set to 8 to 64, more preferably 16 to 48. The braid angle is preferably set to 30 to 60 degrees, more preferably 40 to 50 degrees.

The cylindrical body can be anything other than the braided cord described above and is not particularly limited. For example, an elastic tube made of an elastic material such as polyurethane or silicone may be used. Furthermore, a cylindrical body with deformation characteristics similar to a braided cord can be created by hollowing out a mesh-like structure from a thin cylindrical body molded from a resin or metal material. Additionally, by forming a cylindrical body from a linear material made of resin or metal into a coil spring shape, it is possible to create a cylindrical body that expands and contracts axially and perpendicular to the axis, while also possessing shape recovery properties.

As described above, three-dimensional structural materials can be manufactured by inserting an elongated tubular body into a base material during weaving or knitting. Alternatively, they can be manufactured by inserting an elongated tubular body into a bag-like section of a base material. Furthermore, they can be manufactured by placing a tubular body on a fabric, overlapping it with another fabric to cover it, and then sewing or bonding both sides of the tubular body to form a bag-like section.

The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[Example 1]
<Materials used>
For the base structure, polyester multifilament yarn (167 decitex) and double-covered polyurethane yarn (core yarn: polyurethane yarn 620 decitex, sheath yarn: polyester multifilament yarn 167 decitex) were used as warp threads. Polyester multifilament yarn (167 decitex) was used as the weft thread.
For the tubular body, a polyester monofilament yarn (single yarn diameter 0.2 mm) was used as the linear material.

<Manufacturing of cylindrical bodies>
A wire-like material was set in a braiding machine and braided into a round cord using 32-strand braiding so that the braid angle was between 40 and 50 degrees, resulting in a cylindrical body with a diameter of approximately 8 mm.

The resulting cylindrical body exhibits properties of expanding and contracting in the axial direction as well as in the direction perpendicular to the axis. It was confirmed that after narrowing to a width of approximately 3 mm in its maximum extended state, it returned to its original shape.

<Manufacturing of three-dimensional structural materials>
As shown in Figure 1, a three-dimensional structural material was manufactured by weaving a strip-shaped base portion with three connected bag-like sections using tubular weaving, and by weaving in the tubular sections in an extended state as insert threads. The warp and weft threads were set on the loom, and the tubular sections were set as warp threads in an extended state. The base portion with connected bag-like sections was woven by weaving the base portion in a strip-like shape and connecting the sections at equal intervals along the warp direction, and the tubular sections were woven in such a way that they were inserted into the bag-like sections to obtain the three-dimensional structural material.

The resulting three-dimensional structural material showed that the cylindrical body contained within the bag-like portion expanded, forming a void approximately 8 mm in diameter. It was confirmed that this void possessed shape-recovery properties, returning to its original shape after compression and bending deformation.

Furthermore, it was confirmed that the three-dimensional structural material possesses shape-restoring properties, as the base portion is expandable in the longitudinal direction, and the cylindrical body expands and contracts in accordance with the longitudinal expansion and contraction of the base portion. It was also confirmed that the void portion maintains a continuous pipe-like state from the beginning to the end, demonstrating shape stability. Additionally, when the void portion of the three-dimensional structural material is compressed and deformed, a rebound force is generated in response to the deformation, confirming that it possesses cushioning properties.

[Example 2]
<Materials used>
The same materials as in Example 1 were used.
<Manufacturing of cylindrical bodies>
It was manufactured in the same manner as in Example 1.

<Manufacturing of three-dimensional structural materials>
As shown in Figure 4, a three-dimensional structural material was manufactured by weaving a strip-shaped base portion with connecting parts on both sides of three connected bag-shaped portions using tubular weaving, and weaving in the tubular bodies in an extended state as insert yarn. Similar to Example 1, the tubular bodies were set in the loom along with the warp and weft threads as insert yarn, and the base portion with connected bag-shaped portions and connecting parts was woven by weaving a strip-shaped base fabric at equal intervals along the warp direction and connecting both sides at a predetermined width, and the tubular bodies were woven in such a way that they were inserted into the bag-shaped portions to obtain a three-dimensional structural material.

The resulting three-dimensional structural material showed that the cylindrical body contained within the bag-like portion expanded, forming a void approximately 8 mm in diameter. It was confirmed that this void possessed shape-recovery properties, returning to its original shape after compression and bending deformation.

Furthermore, similar to Example 1, the three-dimensional structural material was found to have a base portion that is expandable in the longitudinal direction, and the cylindrical body expands and contracts in accordance with the longitudinal expansion and contraction of the base portion, thus possessing shape-recovery properties.

Furthermore, it was confirmed that the connecting portion can be attached to another fabric by sewing, and that the three-dimensional structural material deforms in accordance with the deformation of the attached fabric, exhibiting flexibility and shape recovery. It was also confirmed that the void portion maintains a continuous, pipe-like state from start to finish, demonstrating shape stability. Additionally, when the void portion of the three-dimensional structural material is compressed, a rebound force is generated in response to the deformation, confirming that it possesses cushioning properties.

[Example 3]
<Materials used>
The same materials as in Example 1 were used.
<Manufacturing of cylindrical bodies>
It was manufactured in the same manner as in Example 1.

<Manufacturing of three-dimensional structural materials>
As shown in Figure 5, a three-dimensional structural material was manufactured by weaving a strip-shaped base portion with three connected bag-like sections using tubular weaving, weaving in tubular bodies in an extended state as insertion yarns, and narrowing the bag-like sections at predetermined intervals to form fastening sections. Similar to Example 1, tubular bodies were set in the loom along with the warp and weft yarns as insertion yarns, and while weaving a base structure in a strip shape, they were connected at equal intervals along the warp direction, and the width between the connection lines was narrowed to the width of the extended tubular body at predetermined lengths, thereby weaving a base portion with bag-like sections and fastening sections, and at that time, the tubular bodies were woven in so as to be inserted into the bag-like sections to obtain a three-dimensional structural material.

The resulting three-dimensional structural material had a void formed when the cylindrical body contained within the bag-like portion was expanded in diameter. The fastening portion was constricted, preventing the cylindrical body from moving. The void portion partitioned by the fastening portion was found to possess shape recovery properties, returning to its original shape after compression and bending deformation, and also exhibited elasticity compared to the unfastened portion.

Furthermore, similar to Example 1, the three-dimensional structural material exhibits longitudinal flexibility in its base portion. The partitioned voids expand and contract in accordance with the longitudinal expansion and contraction of the base portion, demonstrating shape recovery and elasticity. Additionally, when the voids of the three-dimensional structural material were compressed, a greater rebound force was generated in response to the deformation compared to Example 1, confirming improved cushioning properties.

The three-dimensional structural material according to the present invention is lightweight and flexible, possessing shape recovery and cushioning properties in its voids. Therefore, it can be widely used as a cushioning and shock-absorbing material for various items such as clothing, supports, shoes, mats, cushions, beds, bags, chairs, and car seats. Furthermore, because it exhibits shape stability that maintains a connected state in its voids, it can be used as a sleeve material for inserting wires such as wiring and optical fibers, making it applicable to wearable computer technology. As a highly versatile material, it is expected to be utilized in a wide range of fields.

DESCRIPTION OF SYMBOLS 1... Three-dimensional structure material, 2... Base part, 3... Bag-shaped part, 4... Cylindrical body, 5... Cavity part, 6... Connection part, 7... Fastening part

Claims (7)

A three-dimensional structural material comprising a hollow cylindrical body that expands and contracts in the axial direction and in a direction perpendicular to the axis, and has shape-recovering properties, a void formed inside the cylindrical body , and a base part made of fabric with a bag-like part that encloses the cylindrical body, wherein the cylindrical body is a braided body woven into a cylindrical shape using linear material that has shape-recovering properties. A three-dimensional structural material comprising a hollow cylindrical body that expands and contracts in the axial direction and in a direction perpendicular to the axis, while also having shape-restoring properties; a void formed inside the cylindrical body ; and a base part made of fabric in which a bag-like portion is formed to house the cylindrical body, wherein the void is formed in multiple locations, with each of the bag-like portions formed by arranging multiple cylindrical bodies in parallel. The three-dimensional structural material according to claim 1 or 2, wherein the base portion is made of a fabric in which the bag-shaped portion is integrally woven or knitted. The base portion is made of a stretchable fabric, as described in any one of claims 1 to 3. The three-dimensional structural material according to any one of claims 1 to 4, wherein the void portion is partitioned by the cylindrical body being fastened to a fastening portion that partially seals or narrows the bag-shaped portion. A cushion structure comprising a three-dimensional structural material as described in any one of claims 1 to 5. The three-dimensional structural material according to any one of claims 1 to 4, wherein the void portion is connected in a pipe-like manner so that a linear body can be inserted through it.