U.S. patent application number 13/988364 was filed with the patent office on 2013-09-19 for woven textile and protective sleeve for wire harness using the same.
This patent application is currently assigned to Toray Industries, Inc.. The applicant listed for this patent is Takahiro Furuta, Hiroshi Tsuchikura. Invention is credited to Takahiro Furuta, Hiroshi Tsuchikura.
Application Number | 20130243985 13/988364 |
Document ID | / |
Family ID | 46171699 |
Filed Date | 2013-09-19 |
United States Patent
Application |
20130243985 |
Kind Code |
A1 |
Furuta; Takahiro ; et
al. |
September 19, 2013 |
WOVEN TEXTILE AND PROTECTIVE SLEEVE FOR WIRE HARNESS USING THE
SAME
Abstract
A two- or more ply flat woven textile in which a texture A
including a yarn A and a texture B including a yarn B are
interwoven, wherein the yarn A and the yarn B are both a warp yarn
or both a weft yarn, and shrinkage percentage of the yarn A (SA
(%)) and shrinkage percentage of the yarn B (SB (%)) satisfies a
specific range. The woven textile, when heat is applied, is
spontaneously formed into a tube with a sufficient overlap in the
circumferential direction. The tube provides easy insertion of lead
wires and is able to protect the lead wires reliably without
exposing the inserted lead wires.
Inventors: |
Furuta; Takahiro; (Osaka,
JP) ; Tsuchikura; Hiroshi; (Shiga, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Furuta; Takahiro
Tsuchikura; Hiroshi |
Osaka
Shiga |
|
JP
JP |
|
|
Assignee: |
Toray Industries, Inc.
Chuo-ku, Tokyo
JP
|
Family ID: |
46171699 |
Appl. No.: |
13/988364 |
Filed: |
November 22, 2011 |
PCT Filed: |
November 22, 2011 |
PCT NO: |
PCT/JP2011/076903 |
371 Date: |
May 20, 2013 |
Current U.S.
Class: |
428/36.1 ;
139/291R; 428/91; 442/189; 442/239 |
Current CPC
Class: |
D03D 11/00 20130101;
D03D 15/04 20130101; D03D 1/00 20130101; D10B 2331/301 20130101;
Y10T 442/3065 20150401; Y10T 428/2395 20150401; H02G 3/0462
20130101; D10B 2505/00 20130101; Y10T 442/3472 20150401; D03D 3/02
20130101; D03D 11/02 20130101; D03D 3/005 20130101; Y10T 428/1362
20150115; D10B 2331/021 20130101 |
Class at
Publication: |
428/36.1 ;
442/239; 428/91; 442/189; 139/291.R |
International
Class: |
D03D 11/02 20060101
D03D011/02; D03D 3/02 20060101 D03D003/02; D03D 1/00 20060101
D03D001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 29, 2010 |
JP |
2010-264756 |
Claims
1. A two- or more ply flat woven textile in which a texture A
comprising a yarn A and a texture B comprising a yarn B are
interwoven, wherein said yarn A and said yarn B are both a warp
yarn or both a weft yarn; shrinkage percentage of said yarn A (SA
(%)) and shrinkage percentage of said yarn B (SB (%)) satisfy (1);
and said woven textile, when heat is applied thereto, is formed
into a tube such that a longer direction of said yarn A and said
yarn B is a circumferential direction and said texture A is located
outside said texture B: 10%<(SB-SA)<60% (1).
2. The woven textile according to claim 1, wherein a nap-raised
texture is interwoven into at least one surface of said woven
textile.
3. The woven textile according to claim 1, wherein said yarn A
comprises continuous fibers with a single-yarn fiber diameter 10 to
1000 .mu.m.
4. The woven textile according to claim 1, wherein among fibers
used for the warp yarn or the weft yarn of the woven textile, a
melting point of the fiber with a lowest melting point TC (.degree.
C.) and a melting point of the fiber with a second lowest melting
point TD (.degree. C.) satisfy (2): 40.degree.
C.<(TD-TC)<150.degree. C. (2),
5. The woven textile according to claim 1, wherein a polyphenylene
sulfide fiber and/or a meta-aramid fiber are further interwoven in
addition to said yarn A and said yarn B.
6. The woven textile according to claim 1, which is a protective
sleeve for a wire harness.
7. A process of producing a tubular woven textile comprising
applying heat to the woven textile according to claim 1 so that
said woven textile spontaneously rolls up due to a difference in
shrinkage percentage between said yarn A and said yarn B to form a
tube; the longer direction of said yarn A and said yarn B is the
circumferential direction of the tube; said texture A is located
outside said texture B; and one end and an opposite end of said
woven textile separably overlap each other on the circumference of
the tube, wherein the length of the overlapping portion in the
circumferential direction is 2% or more of the circumferential
length.
8. The process according to claim 7, wherein said tubular woven
textile is a protective sleeve for a wire harness.
9. A tubular woven textile formed such that a flat two-ply woven
textile in which a front surface texture and a back surface texture
are interwoven is rolled up such that the front surface texture is
located outside, wherein one end and an opposite end of said
two-ply woven textile separably overlap each other on the
circumference of the tube; and in said tubular state, a
circumferential length of a yarn arranged in said front surface
texture (LA) and a circumferential length of a yarn arranged in
said back surface texture (LB) satisfy (3):
10%<{(LA-LB)/LA}.times.100 <60% (3).
10. A protective sleeve for a wire harness comprising the tubular
woven textile according to claim 9.
11. The woven textile according to claim 2, wherein said yarn A
comprises continuous fibers with a single-yarn fiber diameter 10 to
1000 .mu.m.
12. The woven textile according to claim 2, wherein among fibers
used for the warp yarn or the weft yarn of the woven textile, a
melting point of the fiber with a lowest melting point TC (.degree.
C.) and a melting point of the fiber with a second lowest melting
point TD (.degree. C.) satisfy (2): 40.degree.
C.<(TD-TC)<150.degree. C. (2).
13. The woven textile according to claim 3, wherein among fibers
used for the warp yarn or the weft yarn of the woven textile, a
melting point of the fiber with a lowest melting point TC (.degree.
C.) and a melting point of the fiber with a second lowest melting
point TD (.degree. C.) satisfy (2): 40.degree.
C.<(TD-TC)<150.degree. C. (2).
14. The woven textile according to claim 2, wherein a polyphenylene
sulfide fiber and/or a meta-aramid fiber are further interwoven in
addition to said yarn A and said yarn B.
15. The woven textile according to claim 3, wherein a polyphenylene
sulfide fiber and/or a meta-aramid fiber are further interwoven in
addition to said yarn A and said yarn B.
16. The woven textile according to claim 4, wherein a polyphenylene
sulfide fiber and/or a meta-aramid fiber are further interwoven in
addition to said yarn A and said yarn B.
17. The woven textile according to claim 2, which is a protective
sleeve for a wire harness.
18. The woven textile according to claim 3, which is a protective
sleeve for a wire harness.
19. The woven textile according to claim 4, which is a protective
sleeve for a wire harness.
20. The woven textile according to claim 5, which is a protective
sleeve for a wire harness.
Description
TECHNICAL FIELD
[0001] This disclosure relates to a woven textile and a protective
sleeve for a wire harness using the same.
BACKGROUND
[0002] Conventionally, in processing a flat woven textile into a
tube, the method in which a woven textile is set at a tubular metal
mold and formed into a tube by heat set has been generally used. To
form a woven textile into a tube using that processing method, a
technique in heat setting is required. The processing cost is high
and, therefore, it is difficult to provide a tube at low cost.
[0003] With increasing use of electrical appliances, the amount of
wire used increases and, accordingly, the amount of protective
sleeve for a wire harness used tends to increase. Protective
sleeves for a wire harness are classified into two types: the open
type having a slit in the length direction and the closed type
having a complete tubular shape. In the case of the closed type,
the operation of attaching or detaching a lead wire must be
performed from an opening at either end. Therefore, operating
efficiency is low. Thus, the open-type is preferably used. However,
the open-type requires tube formation using a metal mold or half
wrapping using adhesive tape and, in addition, lead wires can be
exposed after protection due to the slit opening.
[0004] Thus, a protective sleeve for a wire harness obtained by
attaching a ring to an open-type protective sleeve to prevent the
opening of a slit has been proposed (JP 06-70425 A).
[0005] Further, as a tapeless protective sleeve for a wire harness,
a method of obtaining a tubular open-type protective sleeve by
laminating two sheets has been proposed (JP 2007-297749 A). That
method allows production of a protective sleeve for a wire harness
that does not use tape or a ring.
[0006] Further, a protective sleeve for a wire harness that has an
improved abrasion resistance by arranging a monofilament and a
multifilament for warp and weft has been proposed (WO 2009/111253
A2).
[0007] However, the method of JP '425 does not improve
cost-effectiveness or operability sufficiently because the number
of rings to attach increases when wires are long or a pathway has
many curves.
[0008] The method of JP '749 does not improve cost-effectiveness or
operability sufficiently because, after providing two sheets, one
sheet A is stretched and the other sheet B must be laminated in the
stretched state less than or equal to the sheet A or unstretched
state.
[0009] In the method of WO '253, a tube is formed by heat-curing a
flat woven textile in the tubular state or applying tension to a
yarn in the process of weaving a woven textile. As mentioned above,
such a heat set technique is difficult to implement and requires a
high processing cost. Thus, the operability for protecting a long
and thin member is very poor.
[0010] It could therefore be helpful to provide a protective sleeve
for a wire harness that can reduce production cost, has an
unprecedented excellent operability, further has excellent
softness, flexibility and the like, and can easily provide
functions such as heat-resisting property and flame resistance, and
a woven textile used therefor.
SUMMARY
[0011] The woven textile is a two- or more ply flat woven textile
in which a texture A comprising a yarn A and a texture B comprising
a yarn B are interwoven, [0012] wherein the yarn A and the yarn B
are both a warp yarn or both a weft yarn; [0013] shrinkage
percentage of the yarn A (SA (%)) and shrinkage percentage of the
yarn B (SB (%)) satisfy (1) below; and [0014] the woven textile,
when heat is applied thereto, is formed into a tube such that the
longer direction of the yarn A and the yarn B is the
circumferential direction and the texture A is located outside the
texture B:
[0014] 10%<(SB-SA)<60% (1).
[0015] The process of producing a tubular woven textile is a
process of producing a tubular woven textile, [0016] wherein heat
is applied to the woven textile so that the woven textile
spontaneously rolls up due to the difference in shrinkage
percentage between the yarn A and the yarn B to form a tube; [0017]
the longer direction of the yarn A and the yarn B is the
circumferential direction of the tube; [0018] the texture A is
located outside the texture B; and [0019] one end and the opposite
end of the woven textile separably overlap each other on the
circumference of the tube, wherein the length of the overlapping
portion in the circumferential direction is 2% or more of the
circumferential length.
[0020] The tubular woven textile is a tubular woven textile formed
such that a flat two-ply woven textile in which a front surface
texture and a back surface texture are interwoven is rolled up such
that the front surface texture is located outside, [0021] wherein
one end and the opposite end of the two-ply woven textile separably
overlap each other on the circumference of the tube; and [0022] in
the tubular state described above, the circumferential length of a
yarn arranged in the front surface texture (LA) and the
circumferential length of a yarn arranged in the back surface
texture (LB) satisfy (3) below:
[0022] 10%<{(LA-LB)/LA}.times.100<60% (3).
[0023] The protective sleeve for a wire harness uses the tubular
woven textile obtained by the process of producing a tubular woven
textile or uses the tubular woven textile.
[0024] The woven textile is spontaneously formed into a tube by
utilizing the difference in shrinkage between yarns caused when
heat is applied and, therefore, heat setting using a metal mold or
half wrapping using adhesive tape is not required. Thus, the cost
of production of a tubular woven textile can be reduced.
[0025] In addition, when a tube with a sufficient overlap in the
circumferential direction is formed by adjusting the conditions of
heat to be applied, lead wires inserted into the woven textile will
not be exposed from the tube due to the overlap, and the lead wires
can be protected sufficiently.
[0026] Further, to form the woven textile into a tube, it is not
necessary to use a metal mold, and the woven textile is formed into
a tube only by simple heating immediately before being used, for
example, in a factory where the tube is used. Thus, the woven
textile can be shipped as a flat woven textile before being formed
into a tube, and can be efficiently transported. Furthermore, the
woven textile can be stored in a small space compared to a tube in
the same amount because it can be stored in piles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a weaving design of our two-ply woven textile.
[0028] FIG. 2 is a schematic view illustrating the arrangement of a
warp yarn and a weft yarn in the woven textile of FIG. 1 seen from
the longer direction of the weft yarn (the direction of arrow
I).
[0029] FIG. 3 is a weaving design of our three-ply woven
textile.
[0030] FIG. 4 is a schematic view illustrating the arrangement of a
warp yarn and a weft yarn in the woven textile of FIG. 3 seen from
the longer direction of the weft yarn (the direction of arrow
I).
DESCRIPTION OF SYMBOLS
[0031] A: Yarn A (Weft yarn A) [0032] B: Yarn B (Weft yarn B)
[0033] A': Texture A comprising yarn A [0034] B': Texture B
comprising yarn B [0035] x, y, z and w: Warp yarn
DETAILED DESCRIPTION
Woven Textile
[0036] The woven textile is a two- or more ply flat woven textile
in which a texture A comprising a yarn A and a texture B comprising
a yarn B are interwoven. The texture A and the texture B are
interwoven such that the longer direction of the yarn A and the
longer direction of the yarn B are in the same direction. Namely,
the yarn A and the yarn B are both a warp yarn of the woven textile
or both a weft yarn of the woven textile.
[0037] For the yarn A and the yarn B, shrinkage percentage of the
yarn A (SA (%)) and shrinkage percentage of the yarn B (SB (%))
satisfy 10%<(SB-SA)<60%. When heat is applied to the woven
textile, the texture A and the texture B shrink in the longer
direction of the yarn A and the yarn B, respectively, and because
of such a difference in shrinkage percentage between the yarn A and
the yarn B, the texture B comprising the yarn B shrink more than
the texture A comprising the yarn A. Consequently, the woven
textile bends such that the longer direction of the yarn A and the
yarn B is the circumferential direction and the texture A is
located outside the texture B. Then, upon heating under appropriate
conditions, the woven textile is formed into a tube in which one
end and the opposite end of the woven textile overlap each other on
the circumference. When the tube is long in the longer direction, a
flexible tube made of the woven textile is provided. The
overlapping portion of the woven textile is not adhered. Thus, it
can be separated to form a gap if a slight force is applied and the
gap will close spontaneously if the force is released. For example,
the overlapping portion is opened by hand, and wires are placed
into the tube through the gap. If the hand is released, the tube
returns to the original tube without a gap so that the wires will
not be exposed outside the tube. Thus, the tube formed from the
woven textile can be suitably used as a protective sleeve for a
wire harness. The overlapping portion need not overlap with no gap
being formed and may overlap with a gap through which the wires
will not come out being formed.
[0038] For use as an electricity protective sleeve, the amount of
overlap on the circumference of the woven textile needs to be
appropriate. For that purpose, it is important that the shrinkage
percentage of the yarn A (SA (%)) and shrinkage percentage of the
yarn B (SB (%)) satisfy 10%<(SB-SA)<60%. When the difference
in shrinkage percentage is less than 10%, even if heat is applied
to the woven textile, the amount of overlap is too small, resulting
in an electricity protective sleeve from which wires are easily
exposed. On the other hand, when the difference in shrinkage
percentage is not less than 60%, even if the heating conditions are
mild, the amount of overlap is too large to easily open a gap for
inserting wires, resulting in an electricity protective sleeve with
poor operability. The lower limit of the difference in shrinkage
percentage is preferably 15% or more, and the upper limit is
preferably 50% or less.
[0039] The shrinkage percentage of a yarn is a value measured
according to JIS L 1013 8.18, Section (1) Hot-water shrinkage
percentage B method (filament shrinkage percentage). First, a yarn
with an initial load being applied is marked at two points with a
distance between points of 500 mm. Next, the initial load is
unloaded, and the yarn is immersed in water at 90.degree. C. for 30
minutes, after which the water is lightly wiped off with absorbent
paper or a cloth, and the yarn is dried by wind. The initial load
is applied again, and the distance between the two points is
measured. Then, the shrinkage percentage (%) is calculated from the
following equation. For five randomly selected yarns, the shrinkage
percentage is calculated, and the average of the five values is
rounded to one decimal place. The average value obtained is the
shrinkage percentage of the yarn:
Shrinkage percentage (%)=(500-Length between two points (mm)
measured when an initial load is applied after treating with hot
water)/500.times.100.
[0040] The woven textile may be a three- or more ply woven textile
in which a texture other than the texture A and the texture B is
interwoven as long as the woven textile is not prevented from
bending when heat is applied. Such a texture may be interwoven into
any places outside the texture A, outside of the texture B, or
between the texture A and the texture B. However, from an economic
standpoint, a two-ply woven textile in which only the texture A and
the texture B are interwoven is preferred.
Yarn A, Yarn B
[0041] As a material of the yarn A and the yarn B, any yarn that
satisfies the shrinkage percentage mentioned above can be used and
synthetic fibers are suitably used. Among the synthetic fibers,
polyester is preferably used. For the form of the yarn, a textured
yarn, a multifilament yarn, a monofilament yarn and the like are
used. Among them, a textured yarn such as a single-heater
false-twisted polyester yarn is preferred in view of formability
and low cost.
[0042] The yarn A is preferably made of continuous fibers with a
single-yarn fiber diameter of 10 to 1000 .mu.m. When the
single-yarn fiber diameter is out of this range, the woven textile
sometimes cannot be formed into a tube even if the relation of the
difference in shrinkage percentage from the yarn B is satisfied. In
view of shape stability, formability and the like, the lower limit
of the single-yarn fiber diameter of the yarn A is preferably 150
.mu.m or more, and the upper limit is preferably 600 .mu.m or
less.
[0043] The shrinkage percentage of the yarn A is preferably 1 to
55%. When the shrinkage percentage is in the range of 1 to 55%,
excellent formability and shape stability are provided. The lower
limit of the shrinkage percentage is more preferably 2% or more,
and the upper limit is more preferably 35% or less.
[0044] The total fineness of the yarn A is preferably 60 to 600
dtex. When the total fineness is in this range, shape stability and
protectability improve.
[0045] The method of obtaining the yarn A is not particularly
limited and, for example, in the case of polyester, the yarn A can
be obtained by setting the take-up speed in spinning at about 2000
to 7000 m/min.
[0046] The yarn B preferably has a single-yarn fiber diameter of 3
to 500 .mu.m. When the single-yarn fiber diameter is out of this
range, the woven textile surface is distorted, which can cause
inefficient wiring operation and the like.
[0047] The shrinkage percentage of the yarn B is preferably 10 to
65%. When it is in this range, a woven textile having good
formability and, further, good shape stability can be obtained.
[0048] The method of obtaining the yarn B is not particularly
limited and, for example, in the case of polyester, the yarn B can
be obtained by employing low-speed taking up at a take-up speed in
spinning of 1000 to 2000 m/min or using an unstretched yarn or a
thick and thin yarn.
Nap-Raised Texture
[0049] In the woven textile, it is preferred that a texture like a
nap-raised velvet be interwoven into the outermost surface. If a
nap-raised texture is interwoven into the outermost surface,
scratch-resisting property and heat-resisting property can be
improved when the woven textile is used for a protective sleeve for
a wire harness. The nap-raised portion may be cut or uncut pile.
For the nap-raised portion, it is preferable to use a multifilament
with a single-yarn fiber diameter of 80 to 800 .mu.m to maintain
rigidity. The nap-raised portion may be formed either by a warp
yarn or by a weft yarn. Further, the nap-raised texture may be
provided on the surface that is located outside the tube (outside
of the texture A) or the surface that is located inside the tube
(outside of the texture B) when the woven textile is formed into a
tube. When provided on the surface that is located outside the
tube, heat generation caused by contact between protective sleeves
can be reduced. When provided on the surface that is located inside
the tube, the function of protecting lead wires placed in a tube
improves.
Lowest Melting Point Fiber
[0050] In the woven textile, when the melting point of the fiber
with the lowest melting point (hereinafter referred to as the
lowest melting point fiber) and the fiber with the second lowest
melting point among the fibers used for a warp yarn or a weft yarn
is taken as TC (.degree. C.) and TD (.degree. C.), respectively, it
is preferred that 40.degree. C.<(TD-TC)<150.degree. C. be
satisfied. By arranging such a lowest melting point fiber, the
lowest melting point fiber that melts during heat set is fused with
surrounding fibers, and effects of prevention of fraying in cutting
of the woven textile, further, improvement of shape stability and
the like can be exerted. The lowest melting point fiber may be
arranged either in a warp yarn or a weft yarn.
[0051] Examples of the fiber with a low melting point include
vinylidene, polyvinyl chloride, nylon, polyethylene, polypropylene,
polyurethane, benzoate and the like, from among which such fibers
that satisfy the requirements described above can be selected as
appropriate and used.
PPS Fiber, Meta-Aramid Fiber
[0052] It is also preferred that the woven textile contain a
polyphenylene sulfide fiber (hereinafter referred to as a PPS
fiber) and a meta-aramid fiber in addition to the yarn A and the
yarn B to provide functions such as heat-resisting property and
flame resistance.
Process for Producing Tubular Woven Textile
[0053] In forming the woven textile into a tube by applying heat,
the tube is formed such that one end and the opposite end of the
woven textile overlap on the circumference of the tube and the
length of the overlapping portion in the circumferential direction
is 2% or more of the circumferential length. When the overlapping
portion accounts for 2% or more, after lead wires are inserted into
the tubular woven textile, the lead wires will be protected
sufficiently by the woven textile due to the overlap in the
circumferential direction. Further, the inserted lead wires will
not protrude from the woven textile. The overlapping portion
preferably accounts for not more than 13%. If the overlapping
portion accounts for more than 13%, lead wires cannot be readily
inserted and the operability can be poor.
[0054] Examples of the method of forming the woven textile into a
tube by heat treatment include a method of treatment under such
heat treatment conditions that, taking the direction perpendicular
to the longer direction of the yarn A and the yarn B as the travel
direction, four heat treatment devices are arranged in series in
the travel direction; hot air at 90 to 200.degree. C. is flown into
the heat treatment devices; and the woven textile passes through
the heat treatment devices in 30 to 190 seconds.
[0055] Alternatively, the woven textile may be protected by heating
and shrinking the woven textile in which lead wires are arranged to
be formed into a tube.
Tubular Woven Textile
[0056] When the woven textile is a two-ply woven textile, the
tubular woven textile formed may be a tubular woven textile wherein
the length of the yarn A (LA) and the length of the yarn B (LB) in
the tubular state satisfy 10%<{(LA-LB)/LA}.times.100<60%.
Namely, it is a tubular woven textile formed such that a flat
two-ply woven textile in which a front surface texture and a back
surface texture are interwoven is rolled up such that the front
surface texture is located outside, wherein one end and the
opposite end of the two-ply woven textile separably overlap each
other on the circumference of the tube and, in the tubular state,
the circumferential length of the yarn arranged in the front
surface texture (LE) and the circumferential length of the yarn
arranged in the back surface texture (LF) satisfy
10%<{(LA-LB)/LA}.times.100<60%. The lower limit of
"{(LA-LB)/LA}.times.100" is preferably 20% or more, and the upper
limit is preferably 60% or less.
[0057] The circumferential length of the yarn arranged in the front
surface texture (LA) is a value determined by randomly selecting
five circumferential full-width yarns arranged in the front surface
texture and rounding the average value thereof to one decimal
place. The circumferential length of the yarn arranged in the back
surface texture (LB) is a value determined in the same manner.
Protective Sleeve for Wire Harness
[0058] The woven textile can be readily formed into a tube, and the
tubular woven textile formed has excellent softness flexibility and
operability. Further, the woven textile can be provided with shape
stability by arranging the lowest melting point fiber that
satisfies particular temperature conditions. Furthermore, the woven
textile can be readily provided with functions such as
heat-resisting property and flame resistance by arranging a PPS
fiber or a meta-aramid fiber. Therefore, the woven textile exerts
an extremely excellent effect when used particularly as a
protective sleeve for a wire harness.
[0059] The thickness of the woven textile may be determined
depending on the scratch-resisting protection performance required
when used as a protective sleeve for a wire harness, and the higher
the protection performance required is, the thicker the woven
textile is. For example, in the case of a wire harness pathway that
requires high protection performance, the woven textile preferably
has a gray fabric thickness of 0.5 to 2.0 mm.
EXAMPLES
[0060] The woven textile will now be described in more detail by
way of example. A needle loom was used as a loom to perform
weaving.
Example 1
[0061] As a warp yarn, single-heater false-twist textured polyester
yarns of 330 dtex and 167 dtex was used. As a weft yarn, a yarn
obtained by drawing together three polyester filaments of 90 dtex
with a shrinkage percentage of 15.3% and a polyester monofilament
with a shrinkage percentage of 2.0% and a single-yarn fiber
diameter of 250 .mu.m were used. The weft yarn obtained by drawing
together three polyester filaments is the yarn B (hereinafter
referred to as the weft yarn B), and the weft yarn of a polyester
monofilament is the yarn A (the weft yarn A). These warp yarns and
weft yarns were used to weave a two-ply woven textile with a warp
yarn density=154 yarns/2.54 cm, a weft yarn beat-up density of 22
yarns/cm, and a gray fabric width of 25.5 mm.
[0062] The construction of the two-ply woven textile woven is shown
in FIGS. 1 and 2. In each Figure, A and B each represents a weft
yarn, and x, y, and z each represents a warp yarn. A is the weft
yarn A; B is the weft yarn B; x and y are a single-heater textured
polyester yarn of 330 dtex; and z is a single-heater textured
polyester yarn of 167 dtex. A' is the texture A comprising the weft
yarn A, and B' is the texture B comprising the weft yarn B.
[0063] FIG. 1 is a weaving design that represents on one plane the
way the two-ply woven textile is woven. FIG. 2 is a schematic view
of the woven textile represented by the weaving design of FIG. 1
seen from the longer direction of the weft yarn (the direction of
arrow I), and (1), (2), and (3) each shows how the warp yarns x, y,
and z are beaten up into the weft yarns A and B.
[0064] How to appreciate FIG. 1 is briefly described. The leftmost
"BABABABA" indicates that the texture comprising the weft yarn B is
located at the front of the page and the texture comprising the
weft yarn A is located at the back of the page. The uppermost
"xxxxyzy . . . " indicates that the warp yarns x, y, and z are
beaten up in the order mentioned. A white cell indicates that, at
that part, the warp yarn is located at the back of the page
compared to the weft yarn, and a black cell indicates that, at that
part, the warp yarn is located at the front of the page compared to
the weft yarn. Now looking at every two-cell combination from top
to bottom in the warp yarn direction, "(weft yarn B) white cell,
(weft yarn A) black cell" indicates that a warp yarn is located at
the back of the page compared to the weft yarn B and the front of
the page compared to the weft yarn A, that is, between the weft
yarn B and the weft yarn A. "(Weft yarn B) white cell, (weft yarn
A) white cell" indicates that a warp yarn is located at the back of
the page compared to the weft yarn B and the back of the page
compared to the weft yarn A, that is, at the back of the woven
textile on the page. "(Weft yarn B) black cell, (weft yarn A) black
cell" indicates that a warp yarn is located at the front of the
page compared to the weft yarn B and the front of the page compared
to the weft yarn A, that is, at the front of the woven textile on
the page. In other words, FIG. 1 is a plan view illustrating each
pattern of beating up of a warp yarn shown in FIG. 2.
Example 2
[0065] A two-ply woven textile was woven in the same manner as in
Example 1 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 20.5% and as the weft yarn A a polyester
monofilament with a shrinkage percentage of 6.7% and a single-yarn
fiber diameter of 250 .mu.m.
Example 3
[0066] A two-ply woven textile was woven in the same manner as in
Example 1 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 49.3% and as the weft yarn A a polyester
monofilament with a shrinkage percentage of 2.0% and a single-yarn
fiber diameter of 250 .mu.m.
Example 4
[0067] A two-ply woven textile was woven in the same manner as in
Example 1 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 60.8% and as the weft yarn A a polyester
monofilament with a shrinkage percentage of 2.0% and a single-yarn
fiber diameter of 250 .mu.m.
Example 5
[0068] A two-ply woven textile was woven in the same manner as in
Example 3 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 49.3% (melting point: 255.degree. C.) and
one low melting point fiber of 100 dtex with a melting point of
110.degree. C. "Elder" (available from TORAY INDUSTRIES, INC.). A
tube that prevents fraying of yarns in inserting wires or cutting
the woven textile and has further improved shape stability could be
provided.
Example 6
[0069] As a warp yarn, a single-heater false-twist textured
polyester yarn of 330 dtex was used. As a weft yarn, a yarn
obtained by drawing together three polyester filaments of 90 dtex
with a shrinkage percentage of 49.3% and a polyester monofilament
with a shrinkage percentage of 2.0% and a single-yarn fiber
diameter of 250 .mu.m were used. The weft yarn obtained by drawing
together three polyester filaments is the yarn B (hereinafter
referred to as the weft yarn B), and the weft yarn of a polyester
monofilament is the yarn A (the weft yarn A). These warp yarn and
weft yarn were used to weave a two-ply woven textile with a warp
yarn density=154 yarns/2.54 cm, a weft yarn beat-up density of 22
yarns/cm, and a gray fabric width of 25.5 mm.
[0070] Further, as a pile fabric, a texture using as a warp yarn a
single-heater false-twist textured polyester yarn of 330 dtex, as a
pile a polyester filament of 560 dtex, and as a weft yarn a
single-heater false-twist textured polyester yarn of 330 dtex was
produced, and the polyester filament arranged as a pile was cut to
obtain a nap-raised portion.
[0071] Thus, a three-ply (including the pile fabric) woven textile
was woven. The construction of the three-ply woven textile woven is
shown in FIGS. 3 and 4. In each Figure, A, B, and C each represents
a weft yarn, and x, y, and w each represents a warp yarn. A is the
weft yarn A; B is the weft yarn B; C is the single-heater textured
polyester yarn of 330 dtex arranged as a weft yarn to produce a
pile fabric; x, y, and z are all a single-heater textured polyester
yarn of 330 dtex; and z is the polyester filament of 560 dtex
arranged as a pile.
[0072] FIG. 3 is a weaving design that represents on one plane the
way the two-ply woven textile is woven. FIG. 4 is a schematic view
of the woven textile represented by the weaving design of FIG. 3
seen from the longer direction of the weft yarn (the direction of
arrow I), and (1), (2), (3), and (4) each shows how the warp yarns
x, y, z, and w are beaten up into the weft yarns A, B, and C. How
to appreciate FIG. 3 is the same as how to appreciate FIG. 1, and
thus detailed descriptions are omitted. It should only be noted
that the texture comprising the weft yarn C is located at the
frontmost of the page; the texture comprising the weft yarn A is
located at the backmost of the page; the texture comprising the
weft yarn B is located between these two textures; and every
three-cell combination is looked from top to bottom in the warp
yarn direction.
Example 7
[0073] A two-ply woven textile was woven in the same manner as in
Example 3 except using as a warp yarn a polyphenylene sulfide fiber
of 330 dtex and 167 dtex.
[0074] x and y in FIGS. 1 and 2 are polyphenylene sulfide fibers of
330 dtex, and z is a polyphenylene sulfide fiber of 167 dtex.
Comparative Example 1
[0075] A two-ply woven textile was woven in the same manner as in
Example 1 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 11.3% and as the weft yarn A a polyester
monofilament with a shrinkage percentage of 2.0% and a single-yarn
fiber diameter of 250 .mu.m.
Comparative Example 2
[0076] A two-ply woven textile was woven in the same manner as in
Example 1 except using as the weft yarn B a yarn obtained by
drawing together three polyester filaments of 90 dtex with a
shrinkage percentage of 66.1% and as the weft yarn B a polyester
monofilament with a shrinkage percentage of 2.0% and a single-yarn
fiber diameter of 250 .mu.m.
Comparative Example 3
[0077] Using the same warp yarn and weft yarn as in Example 3, a
single-ply woven textile of plain construction with a warp yarn
density=154 yarns/2.54 cm, a beat-up density 22 times/cm, and a
gray fabric width of 25.5 mm was woven.
Comparative Example 4
[0078] Using the same warp yarn and weft yarn as in Example 3, a
single-ply woven textile of 2/2 twill construction with a warp yarn
density=154 yarns/2.54 cm, a beat-up density 22 times/cm, and a
gray fabric width of 25.5 mm was woven.
Evaluation
[0079] From the woven textiles woven in Examples 1 to 7 and
Comparative Examples 1 to 4, samples with a length (in the warp
yarn direction) of 1000 mm and a width (in the weft yarn direction)
of 25.5 mm were collected. Each sample was left to stand in a heat
treatment device at 160.degree. C. for 50 seconds. The shape of the
woven textile after the heat treatment is shown in Table 1.
TABLE-US-00001 TABLE 1 Difference Percentage Shrinkage Shrinkage in
Overlap in of Percentage of Percentage of Shrinkage Circumferential
Yarn Length Weft Yarn B Weft Yarn A Percentage Direction Difference
(%) (%) (%) Fabric Construction (%) (%) Example 1 15.3 2.0 13.3
Two-ply shown in FIGS. 1 and 2 2.4 12.3 Example 2 20.5 6.7 13.8
Two-ply shown in FIGS. 1 and 2 2.8 14.3 Example 3 49.3 2.0 47.3
Two-ply shown in FIGS. 1 and 2 8.5 32.6 Example 4 60.8 2.0 58.8
Two-ply shown in FIGS. 1 and 2 11.7 53.3 Example 5 49.3 2.0 47.3
Two-ply shown in FIGS. 1 and 2 8.8 32.6 Example 6 49.3 2.0 47.3
Three-ply shown in FIGS. 3 and 4 8.8 (32.6) Example 7 49.3 2.0 47.3
Two-ply shown in FIGS. 1 and 2 8.8 32.6 Comparative Example 1 11.3
2.0 9.3 Two-ply shown in FIGS. 1 and 2 1.3 9.2 Comparative Example
2 66.1 2.0 64.1 Two-ply shown in FIGS. 1 and 2 14.7 62.2
Comparative Example 3 49.3 2.0 47.3 Plain fabric Not overlapped --
Comparative Example 4 49.3 2.0 47.3 Twill fabric Not overlapped
--
[0080] "Percentage of yarn length difference" is a value of
{(Length of weft yarn A-Length of weft yarn B)/Length of weft yarn
A}.times.100 for both of the two-ply woven textiles and the
three-ply woven textile. The woven textile in Example 6 is a
three-ply, and thus the "percentage of yarn length difference" is
described as a reference value because it is not a percentage of
yarn length difference between the weft yarn of a front surface
texture and the weft yarn of a back surface texture.
[0081] Further, ease of operation (operability) in actually
inserting lead wires into a woven textile and whether the shape of
the woven textile was retained after the insertion operation (shape
stability) were examined.
[0082] The woven textile in Example 1 was formed into a tube having
an overlap in the circumferential direction. However, it had low
bendability because of somewhat small difference in shrinkage
percentage between the weft yarn A and the weft yarn B. Therefore,
the woven textile sometimes did not overlap successfully during the
operation of inserting lead wires, and the shape stability was
somewhat insufficient. Accordingly, it was necessary to carry out
the operation while adjusting the woven textile to overlap the way
it was, and the operability was also somewhat insufficient.
[0083] The woven textiles in Examples 2 to 7 were all a tube having
a sufficient overlap in the circumferential direction and preferred
as a protective sleeve for a wire harness. In addition, it was easy
to open the overlapping portion to form a gap, and an operation of
inserting lead wires could be easily performed. Further, because
the tube overlaps the way it was when hands were released, the
shape stability was excellent and the wire protectability after the
operation was sufficient.
[0084] In addition, the woven textiles in Examples 5 to 7 also had
characteristics as follows: [0085] The woven textile in Example 5
provided a protective sleeve for a wire harness having particularly
good shape stability and operability compared to the woven textile
in Example 3 because the low melting point fiber arranged in the
woven textile melted and fused with surrounding fibers; [0086] The
woven textile in Example 6 was a tube with pile fabric interior,
and the nap-raised portion improved lead-wire protection
performance; and [0087] The woven textile in Example 7 had an
improved heat-resisting property and flame resistance because a
polyphenylene sulfide fiber was used as a warp yarn.
[0088] In contrast, the woven textile in Comparative Example 1
provided an irregular tube after heat treatment. In addition, the
overlap in the circumferential direction disappeared after the
operation of inserting lead wires, and there was a problem in
protectability for lead wires. Therefore, the inserted lead wires
protruded externally, and the operability was poor.
[0089] The woven textile in Comparative Example 2 was a tube having
a sufficient overlap in the circumferential direction, but because
of too large overlap in the circumferential direction, it was
difficult to open the overlapping portion to form a gap. Thus, it
was difficult to carry out the operation of inserting lead wires.
In addition, because of the large overlapping portion, it was a
tube lacking in softness.
[0090] The woven textiles in Comparative Example 3 and 4 were not
formed into a tube and could not protect lead wires.
* * * * *