U.S. patent application number 16/497807 was filed with the patent office on 2021-04-15 for thermo-shapeable fabrics and articles made therefrom.
This patent application is currently assigned to MINIWIZ CO.,LTD.. The applicant listed for this patent is MINIWIZ CO.,LTD.. Invention is credited to Yi-Chun CHANG, Chian-Chi HUANG, GUILLEMETTE-PAULINE-MARION LEGRAND, Tzu-Wei LIU, CAMILLE-JEANNE TEXIER, Ling-Hsiang WENG.
Application Number | 20210108341 16/497807 |
Document ID | / |
Family ID | 1000005339651 |
Filed Date | 2021-04-15 |
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United States Patent
Application |
20210108341 |
Kind Code |
A1 |
HUANG; Chian-Chi ; et
al. |
April 15, 2021 |
THERMO-SHAPEABLE FABRICS AND ARTICLES MADE THEREFROM
Abstract
Disclosed herein are fabrics having different thermo-properties.
The fabric is characterized in its structure by having a high
melting temperature zone and a low melting temperature zone, which
are respectively made up by yarns having high and low melting
temperatures By having yarns of high and low temperatures in the
fabric, in which the respective melting temperatures in the high
and low melting temperature zones differ by about 30.degree. C. to
150.degree. C.; and the low melting temperature zone melts and
eventually becomes harden after heat-activation, while the high
melting temperature zone remains un-melted and soft after
heat-activation.
Inventors: |
HUANG; Chian-Chi; (Taipei
City, TW) ; LIU; Tzu-Wei; (Taipei City, TW) ;
CHANG; Yi-Chun; (Taipei City, TW) ; WENG;
Ling-Hsiang; (Taipei City, TW) ; LEGRAND;
GUILLEMETTE-PAULINE-MARION; (Taipei City, TW) ;
TEXIER; CAMILLE-JEANNE; (Taipei City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MINIWIZ CO.,LTD. |
Taipei City |
|
TW |
|
|
Assignee: |
MINIWIZ CO.,LTD.
Taipei City
TW
|
Family ID: |
1000005339651 |
Appl. No.: |
16/497807 |
Filed: |
March 29, 2018 |
PCT Filed: |
March 29, 2018 |
PCT NO: |
PCT/CN2018/081121 |
371 Date: |
September 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62478611 |
Mar 30, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 15/567 20210101;
D02G 3/02 20130101; D02G 3/44 20130101; D10B 2401/041 20130101;
D01F 6/62 20130101; D10B 2331/04 20130101; D01F 8/14 20130101 |
International
Class: |
D02G 3/44 20060101
D02G003/44; D01F 6/62 20060101 D01F006/62; D01F 8/14 20060101
D01F008/14; D03D 15/567 20060101 D03D015/567; D02G 3/02 20060101
D02G003/02 |
Claims
1. A thermo-shapeable fabric comprising: a high melting temperature
zone and a low melting temperature zone respectively composed of
yarns having high and low melting temperatures, wherein, the
respective melting temperatures in the high and low melting
temperature zones differ by about 30.degree. C. to 150.degree. C.;
and the low melting temperature zone becomes harden after
heat-activation, while the high melting temperature zone remains
soft after heat-activation.
2. The thermo-shapeable fabric of claim 1, wherein each yarns is
composed of a plurality of fibers independently made from
polyethylene terephthalate (PET), low melting point copolyester, or
a combination thereof.
3. The thermo-shapeable fabric of claim 1, wherein the low melting
point copolyester is a copolymer of terephthalic acid (PTA),
ethylene glycol (EG) and an aliphatic monomer, in which the
aliphatic monomer is selected from the group consisting of glutamic
acid, adipic acid, pimelic acid, suberic acid, sebacic acid,
neopentyl glycol and butylene glycol.
4. The thermo-shapeable fabric of claim 3, wherein the low melting
point copolyester is a copolymer of PTA, EG and sebacic acid.
5. The thermo-shapeable fabric of claim 1, wherein the low
temperature zone is created by embroidering the yarns having low
melting temperature onto the high melting temperature zone.
6. The thermo-shapeable fabric of claim 1, wherein the high and low
temperature zones are created by knitting or weaving the yarns
respectively having high and low melting temperature into the
thermo-shapeable fabric.
7. The thermo-shapeable fabric of claim 1, wherein the
heat-activation comprises heating the thermo-shapeable fabric until
the temperature reaches the melting temperature of the low
temperature zone but not exceeding the melting temperature of the
high temperature zone.
8. An article made by heat-activating the thermo-shapeable fabric
of claim 1 to form a shape of the article directly on the
thermo-shapeable fabric.
9. The article of claim 8, wherein the shape of the article is
created by heating the thermo-shapeable fabric of claim 1 until the
temperature reaches the melting temperature of the low temperature
zone but not exceeding the melting temperature of the high
temperature zone.
10. The article of claim 9, wherein the shape of the article is
created with an aid of a mould during the heat activation.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 USC section
119(e) to U.S. Provisional Application No. 62/478,611 filed Mar.
30, 2017, which is incorporated by reference herein as if fully set
forth.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present disclosure relates to the technical field of
textiles. More particularly, the disclosure invention relates to
fabrics having different thermo-properties, and 3D articles made
therefrom.
2. Description of Related Art
[0003] Conventionally, in textile industry, thermo-shapeable fibers
are used to form shapeable layers that are laminated with layers of
thermoplastic fibers to form textile layer (e.g., non-woven
fabric). However, no one has ever tried producing textile fabric by
directly knitting or weaving thermo-shapeable fibers into a fabric
thereby creating a textile having thermo-shapeable property.
[0004] Inventors of the present disclosure unexpectedly created a
smart textile by knitting, weaving or embroidering yarns of high
and low melting temperatures into a fabric, thereby rendering the
fiber thermo-shapeable property that allows 3D articles to be
created directly from the fabric after heat-activation.
SUMMARY
[0005] The following presents a simplified summary of the
disclosure in order to provide a basic understanding to the reader.
This summary is not an extensive overview of the disclosure and it
does not identify key/critical elements of the present invention or
delineate the scope of the present invention. Its sole purpose is
to present some concepts disclosed herein in a simplified form as a
prelude to the more detailed description that is presented
later.
[0006] In general, the present disclosure is directed to economical
formation of textile articles (e.g., shoulder pads, triglide
buckles, pockets and etc) directly out from a thermo-shapeable
fabric.
[0007] Accordingly, one aspect of the present disclosure is
directed to fabrics having different thermo-properties. The fabric
comprises in its structure, a high melting temperature zone and a
low melting temperature zone respectively composed of yarns of high
and low melting temperatures, in which the respective melting
temperatures in the high and low melting temperature zones differ
by about 30.degree. C. to 150.degree. C.; and the low melting
temperature zone becomes harden after heat-activation, while the
high melting temperature zone remains soft after
heat-activation.
[0008] According to embodiments of the present disclosure, each
yarns is composed of a plurality of fibers independently made from
polyester (PES), which includes but is not limited to polyethylene
terephthalate (PET), low melting point copolyester, and a
combination thereof.
[0009] According to embodiments of the present disclosure, the low
melting point copolyester is a copolymer of terephthalic acid
(PTA), ethylene glycol (EG) and an aliphatic monomer. The aliphatic
monomer may be any of glutamic acid, adipic acid, pimelic acid,
suberic acid, sebacic acid, neopentyl glycol or butylene glycol,
and accounts for 1-20% (wt %) of the total weight of the copolymer.
Preferably, the low melting point copolyester of the present
disclosure is a copolymer of PTA, EG, and sebacic acid.
[0010] According to embodiments of the present disclosure, the low
temperature zone is created by embroidering the yarns having low
melting temperature onto the high melting temperature zone.
[0011] According to embodiments of the present disclosure, the high
and low temperature zone are created by knitting or weaving the
yarns respectively having high and low melting temperature into the
thermo-shapeable fabric.
[0012] According to embodiments of the present disclosure, the
heat-activation is achieved by heating the thermo-shapeable fabric
until the temperature reaches the melting temperature of the low
temperature zone but not exceeding the melting temperature of the
high temperature zone.
[0013] Accordingly, a further aspect of the present disclosure is
directed to an article made by heat-activating the present
thermo-shapeable fabric into forming certain shape, thereby
producing the article directly on the thermo-shapeable fabric.
[0014] According to embodiments of the present disclosure, the
shape of the article is created by heating the present
thermo-shapeable fabric until the temperature reaches the melting
temperature of the low temperature zone but not exceeding the
melting temperature of the high temperature zone.
[0015] According to certain embodiments of the present disclosure,
the shape of the article is created by use of a mould during the
heat activation.
[0016] Many of the attendant features and advantages of the present
disclosure will becomes better understood with reference to the
following detailed description considered in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawing(s) will be provided by the Office
upon request and payment of the necessary fee.
[0018] The present description will be better understood from the
following detailed description read in light of the accompanying
drawings, where:
[0019] FIG. 1A is a schematic diagram of a yarn composed of
core-sheath composite fibers in accordance with one embodiment of
the present disclosure;
[0020] FIG. 1B is the cross-sectional view of the yarn depicted in
FIG. 1A taken along the line 1-1';
[0021] FIG. 2A is a schematic diagram of a yarn composed of
comingled fibers in accordance with another embodiment of the
present disclosure;
[0022] FIG. 2B is the cross-sectional view of the yarn depicted in
FIG. 2A taken along the line 2-2';
[0023] FIG. 3A is a schematic diagram of a yarn composed of twisted
fibers in accordance with one embodiment of the present
disclosure;
[0024] FIG. 3B is the cross-sectional view of the yarn depicted in
FIG. 3A taken along the line 3-3';
[0025] FIG. 4A is a schematic diagram of a yarn composed of hollow
core fibers in accordance with one embodiment of the present
disclosure;
[0026] FIG. 4B is the cross-sectional view of the yarn depicted in
FIG. 4A taken along the line 4-4';
[0027] FIG. 5 is a photograph depicting a fabric carrying an
2D-grid pattern embroidered via a 6-heads embroidery machine in
accordance with one embodiment of the present disclosure;
[0028] FIG. 6 is a photograph depicting a fabric carrying
heat-activated pattern embroidered via machine with cording device
in accordance with one embodiment of the present disclosure;
[0029] FIG. 7 is photograph depicting a thermo-shaped article made
from a fabric carrying a pattern embroidered by a 6-heads
embroidery machine in accordance with one embodiment of the present
disclosure;
[0030] FIG. 8A is a photograph depicting a thermo-shapeable fabric
manufactured in accordance with one embodiment of the present
disclosure;
[0031] FIG. 8B is a photograph depicting the thermo-shapeable
fabric of FIG. 8A after heat-activation;
[0032] FIG. 9 is a photograph depicting a rectangular article made
by thermo-shapeable fabric in accordance with one embodiment of the
present disclosure;
[0033] FIG. 10 is a photograph depicting a triglide buckle made by
thermo-shapeable fabric in accordance with one embodiment of the
present disclosure;
[0034] FIG. 11 a photograph depicting a 3-D rectangular shape
created by heat-activing a thermo-shapeable fabric produced by
Double Jacquard knit in accordance with one embodiment of the
present disclosure; and
[0035] FIG. 12 is a photograph depicting two sides of a
thermo-shapeable fabrics produced by Double Jacquard knit in
accordance with another embodiment of the present disclosure, in
which the front side of the fabric is in blue, while the back side
of the fabric is in white.
[0036] In accordance with common practice, the various described
features/elements are not drawn to scale but instead are drawn to
best illustrate specific features/elements relevant to the present
invention. Also, like reference numerals and designations in the
various drawings are used to indicate like elements/parts.
DESCRIPTION
[0037] The detailed description provided below in connection with
the appended drawings is intended as a description of the present
examples and is not intended to represent the only forms in which
the present example may be constructed or utilized. The description
sets forth the functions of the example and the sequence of steps
for constructing and operating the example. However, the same or
equivalent functions and sequences may be accomplished by different
examples.
[0038] The singular forms "a," "and," and "the" are used herein to
include plural referents unless the context clearly dictates
otherwise.
[0039] In general, the present disclosure is directed to economical
formation of textile articles (e.g., shoulder pads, buttons,
pockets and etc) directly out from a thermo-shapeable fabric.
[0040] To this purpose, polymeric fibers or filaments (e.g., low
melting point copolyester or PET fibers) are combined to form
yarns, which are then strategically embroidered, knitted and/or
woven into fabric to create the desired thermo-shapeable fabric, on
which zones of high and low melting temperatures are found. Upon
contacting with heat, parts of the fabric having zones of low
melting temperature would melt and eventually become harden, while
parts of the fabric having zones of high melting temperature remain
un-melted and soft, thereby creating articles (e.g., pockets) with
certain 3-dimensional shapes directly on the fabric, alternatively
the fabric having harden and soft areas may be folded in desire
manner to create 3D articles.
[0041] 1. Filaments
[0042] The terms "filaments" and "fibers" are used interchangeably
herein to refer continuous strands of materials. In the present
disclosure, desirable filaments or fibers are made from polyesters
(PES), which may be polyethylene terephthalate (PET) or low melting
point copolyester; preferably, from recycled material, so as to
reduce the carbon footage of an article eventually manufactured
therefrom.
[0043] The term "low melting point copolyester" as used herein
refers to a modified polyester, such as a copolymer of terephthalic
acid (PTA), ethylene glycol (EG) and an aliphatic monomer. The
aliphatic monomer may be any of glutamic acid, adipic acid, pimelic
acid, suberic acid, sebacic acid, neoentyl glycol or butylene
glycol. Terephalic acid (PTA) and ethylene glycol (EG) are
respective monomers of polyethylene terephthalate (PET). During
polymerization, PTA and EG will polymerize to form PET, however, in
the presence of the aliphatic monomer, in addition to PET chain,
block copolymer between aliphatic monomer and PTA or EG may be
formed also, accordingly, a modified PET comprising blocks of
colpolymer of PET/aliphatic monomer, are formed. The crystalline
property of the thus modified PET or copolyester differ from that
of the un-modified PET (i.e., PET without the addition of aliphatic
monomer) in that the melting point of the modified PET is much
lower than that of the un-modified PET. The reduction in melting
point of PET is inversely proportional to the amount of aliphatic
monomer present in the copolymer, in other words, the lower the
melting point, the higher level of aliphatic monomer may be present
in the copolymer. Preferably, the aliphatic monomer accounts for
about 1-20% (wt %) of the copolyester.
[0044] According to preferred embodiments of the present
disclosure, the low melting point copolyesters are copolymers of
PTA, EG and sebacic acid. In the present disclosure, the low
melting point copolyester has a melting point ranging from 110 to
230.degree. C., while the PET has a melting point that is
approximately 250-260.degree. C. Accordingly, yarns formed by PET
fibers will have a melting point much higher than those formed by
low melting point copolyester fibers. Low melting copolyesters
suitable for use in the present disclosure are also available
commercially, such as SRPX.TM. filaments (Miniwiz, Taipei,
Taiwan).
[0045] The polymeric filament suitable for use in the present
disclosure are produced by conventional technique, such as
spinning. In some embodiments, the polymeric filament is in the
structure of a core-sheath composite fiber, where the fiber
comprises a core component and a sheath component, in which the
sheath component is disposed about the periphery of the core
component. Preferably, the core and the sheath components are made
from polymeric materials of different melting temperatures, thereby
creating different thermo-properties on the fibers. Alternatively,
the polymeric filament may comprise a lumen or a hollow core.
[0046] 2. Yarns
[0047] Various types of yarns are formed and used in the present
disclosure, in general, they are produced by conventional
technique, except fibers composed of recycled material and/or the
combination of virgin and recycled material are included to produce
yarns. Depending on the manufacturing technique, yarns thus
produced may come in various structures and shapes. Accordingly,
the yarn may have cross-section that is round, trilobal,
multilobal, orange slice and etc.
[0048] Throughout the text of the present disclosure, the term
"yarns of high temperature" refers to yarns that are composed of
filaments having high melting temperature, such as yarns composed
of filaments made of PET; and the term "yarns of low temperature"
refers to yarns that are composed of filaments having low melting
temperature, such as yarns composed of filaments made of low
melting point copolyester (such as SRPX.TM. filaments (Miniwiz,
Taipei, Taiwan)).
[0049] 2.1 Yarns Composed of Core-Sheath Composite Fibers
[0050] References are made to FIGS. 1A and 1B, in which FIG. 1A is
a schematic diagram of a yarn 10; and FIG. 1B is the
cross-sectional view of the yarn 10 taken along the line 1-1'. As
depicted in FIG. 1A, the yarn 10 is composed of a plurality of a
polymeric filament 11. The cross-sectional view of the yarn 10
taken along the line 1-1' reveals that each polymeric filament 11
is a core-sheath composite fiber, in which each fiber comprises a
core component 11C and a sheath component 11S. The core and the
sheath components may be respectively made from low melting point
copolyester and PET, and vice versa. According to one embodiment of
the present disclosure, the core is composed of PET, while the
sheath is composed of low melting point copolyester. In another
embodiment, the core is made of low melting point copolyester,
while the sheath is composed of PET.
[0051] 2.2 Yarns Composed of Comingled Fibers
[0052] References are made to FIGS. 2A and 2B, in which FIG. 2A is
a schematic diagram of a yarn 20; and FIG. 2B is the
cross-sectional view of the yarn 20 taken along the line 2-2'. In
this embodiment, the yarn 20 is composed of a plurality of a first
and second polymeric filaments 21, 22 co-mingled therein. The first
and second polymeric filaments 21, 22 are respectively
mono-component fibers made from low melting point copolyester and
PET, and vice versa. According to one embodiment of the present
disclosure, the first polymeric filaments are made from low melting
point copolyester, while the second polymeric filaments are made
from PET.
[0053] 2.3 Twisting Yarns
[0054] References are made to FIGS. 3A and 3B, in which FIG. 3A is
a schematic diagram of a single covered yarn 30; and FIG. 3B is the
cross-sectional view of the yarn 30 taken along the line 3-3'. In
this embodiment, the yarn 30 is composed of a plurality of a first
and second polymeric filaments 31, 32 respectively serve as the
core and twisting fibers, in which the directions of the second
polymeric filaments (or the twisting fibers) are twisted and turned
about the first filaments (or the core fibers) during the
manufacturing process to bring the two polymeric fibers close
together and makes the structure of the yarn 30 more compact. Twist
is a common technique used in textile industry, it helps the fibers
adhere to one another, increasing yarn strength. The direction and
amount of yarn twist helps determine appearance, performance,
durability of the yarns and the subsequent fabric or textile
product.
[0055] When manufacturing the twisting yarns, the core fibers may
be filaments having higher melting point (e.g., PET), while the
twisting fibers are filaments having low melting temperature (e.g.,
low melting point copolyester). Alternatively, both the core fibers
and the twisting fibers may be core-sheath composite fibers, in
which the core is made of material having relatively higher melting
point (e.g., PET) and the sheath is made of material having
relatively lower melting point (e.g., low melting point
copolyester).
[0056] According to some embodiments of the present disclosure,
single covered yarns comprise core fibers and twisting fibers
respectively made of low melting point copolyester, are produced.
In other embodiments, double covered yarns are made, in such case,
the core fibers are made of PET, and the twisting fibers are made
of low melting point copolyester. In still further embodiments,
cable double ply yarns composed of core-sheath composite fibers are
made, in which the core component of the composite fiber is made of
PET, and the sheath component is made of low melting point
copolyester.
[0057] 2.4 Yarns Composed of Hollow Core Fibers
[0058] References are made to FIGS. 4A and 4B, in which FIG. 4A is
a schematic diagram of a yarn 40; and FIG. 4B is the
cross-sectional view of the yarn 40 taken along the line 4-4'. In
this embodiment, the yarn 40 is composed of a plurality of a
polymeric filament 41 that are hollow core fibers, in which each
fiber has a lumen or a hollow core. In certain embodiments, the
hollow core fibers are made of PET, e.g., recycled PET.
[0059] 3. Thermo-Shapeable Fabric and Articles Made Therefrom
[0060] To produce fabrics having thermo-shapeable property, yarns
composed of filaments having high or low melting temperatures are
strategically embroidered, knitted or woven into fabrics, so that
areas or zones having desired temperature distribution are created
on the fabrics, rendering the fabrics shapeable by heat.
[0061] Preferably, the thermo-shapeable fabric shall contain high
and low temperature zones, in which the melting temperature of
yarns of high temperature differs from that of the yarns of low
temperature by 30-150.degree. C., such as 30, 31, 32, 33, 34, 35,
36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52,
53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69,
70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86,
87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102,
103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115,
116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128,
129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141,
142, 143, 144, 145, 146, 147, 148, 149 and 150.degree. C. A person
having ordinary skill in the related art would be able to choose
suitable yarns of high and low temperatures and create a fabric
having desired thermo-shapeable property without undue
experimentation.
[0062] 3.1 Thermo-Shapeable Fabric Created by Embroidery Technique
and Articles Made Therefrom
[0063] According to some preferred embodiments, yarns of low
temperature are embroidered onto a base fabric made of yarns of
high temperature, and forms a particular pattern (e.g., FIG. 6).
Alternatively, multiple layers of the pre-designed pattern
respectively formed by yarns of low temperature may be embroidered
onto a base fabric (FIG. 5), so as to enhance the mechanical
strength of the article intended to be made therefrom. In such
cases, as the embroidered pattern is mainly composed of yarns of
low temperature (e.g., core-sheath composite filaments made of low
melting point copolyester), and the base fabric is composed of
yarns of high temperature (e.g., PET), thus, when the temperature
of the fabric is raised to a point exceeding the melting
temperature of the yarns of low temperature, then yarns in these
areas will melt and subsequently become harden once the temperature
is dropped; while at the same time, zones composed of yarns of high
temperature remain soft, as yarns in these areas stay un-melted. An
article created by such manner is depicted in FIG. 7 in accordance
to one specific embodiment of the present disclosure. A person
having ordinary skill in the related art would be able to choose
suitable combination of yarns of high and low temperatures and
create desirable pattern using any embroidery technique he/she
deems appropriate, such that the embroidered pattern can eventually
turn into articles of desired shape.
[0064] 3.2 Thermo-Shapeable Fabric Created by Knitting Technique
and Articles Made Therefrom
[0065] According to some preferred embodiments, yarns of high and
low temperatures are strategically knitted into a fabric, thereby
creating zones having different thermo-properties on the fabric.
Any conventional knitting method may be used to knit yarns of the
present disclosure into a fabric, exemplary knitting method
includes, but is not limited to, seamless, Jacquard, Double
Jacquard, quilting double Jacquard knit, birdseye Jacquard, single
jacquard knit, warp knit, cross tubular, jersey, rib, interlock,
and etc.
[0066] Reference is made to FIG. 8A, in which a fabric formed by
Jacquard knitting yarns of high and low temperatures is depicted in
accordance with one particular embodiment of the present
disclosure. The straight lines and lines defining each diamond
shapes are composed of yarns of high temperature (e.g., PET
fibers), whereas the other areas are composed of yarns of low
temperature (e.g., low melting point copolyester), thereby creating
zones of different thermo-properties on the fabric. Depending on
the size and/or shape of an article intended to be made from the
fabric, sufficient amount of heat may then be applied to the
intended area, so that yarns in the zones of low temperature (i.e.,
the diamond shape areas) are melted, and subsequently become harden
after the temperature is dropped, while the lines remain soft
throughout the heat activation process (FIG. 8B). Accordingly, the
fabric can be folded into desirable 3D shape without using
conventional cutting, quilting or molding technique.
[0067] FIGS. 9 and 10 are photographs of another two articles
respectively made from fabrics manufactured by Jacquard knitting
described above. By similar manner, fabrics made by Double Jacquard
knitting are depicted in FIGS. 11 and 12, and similar to the fabric
made by Jacquard knitting, these fabrics mat also be shaped by
heat, in which a 3D rectangular shape is formed by heat-activation
on the Double Jacquard knitted fabric of FIG. 11.
[0068] 3.3 Thermo-Shapeable Fabric Created by Woven Technique and
Articles Made Therefrom
[0069] According to additional embodiments, yarns of high and low
temperatures are strategically woven into a fabric, thereby
creating zones having different thermo-properties on the fabric.
Any conventional weaving method may be used to weave yarns of the
present disclosure into a fabric, exemplary weaving method
includes, but is not limited to, double sided woven, Jacquard, Fil
Coupe, and etc.
[0070] Similar to fabrics produced by embroidery or knitting
technique described above, fabrics produced by weaving technique
are also thermo-shapeable due to the inclusion of yarns of high and
low temperatures during the weaving process.
[0071] Hereinafter, the present invention will be described in
detail with reference to the following examples, which are provided
to illustrate aspects of the present invention, but the scope of
the preset invention is not limited to those examples.
EXAMPLES
Example 1 Manufacture of Yarns
[0072] In this example, yarns capable of melting at two different
temperatures were manufactured by use of one or more types of
filaments composed of one or two components having different
melting temperatures. The filaments used in this example were
produced by conventional spinning technique and were made into
fibers having various shapes, thereby producing cross-sections that
were round, trilobal, multilobal, round hollow (resulted from
hollow core filaments), or orange slice. For core-sheath composite
filaments, the core and sheath components in each filaments were
respectively 50/50 or 80/20.
[0073] 1.1 Yarns Composed of Core-Sheath Composite Fibers
[0074] A total number of 16 to 192 core-sheath composite filaments
about 30-450 Denier (D) were gathered to form yarns. In this
example, each core-sheath composite fibers comprised a core
component made of PET (i.e., having a melting temperature about
260.degree. C.), and a sheath made of low melting point copolyester
(i.e., having a melting temperature ranging from about
110-230.degree. C.). Then, various sections of the thus produced
yarns were respectively taken, including orange slice, round,
trilobal, multilobal, and cross section, which independently
revealed that the yarn comprised about 5 to 80% low melting point
fibers.
[0075] 1.2 Yarns Composed of Core-Sheath Composite Fibers
[0076] The yarns in this example were manufactured in accordance
with the procedures described in Example 1.1, except each
core-sheath composite fibers comprised a core component made of low
melting point copolyester (i.e., low temperature material), and a
sheath component made of PET (i.e., high temperature material).
[0077] 1.3 Twisting Yarns
[0078] In this example, 3 types of twisting yarns, including single
covered yarns, double covered yarns, and cable double pli, were
respectively produced in accordance with conventional processes of
making such yarns. The single covered yarn comprised one strand of
core fibers made of PET fibers of 300D, and one strand of twisting
fibers made of low melting point copolyester fibers of 150D. The
double covered yarn comprised one strand of core fibers made of
PET, and two strands of twisting fibers respectively twisted around
the cord fibers in opposite directions. In the cable double pli,
both the core fibers and the twisting fibers were core-sheath
composite fibers, in which the cord component in each composite
fibers was made of PET, and the sheath component was made of low
melting point copolyester.
[0079] 1.4 Yarns Composed of Hollow Cord PET Fibers
[0080] In this example, a total number of 16 to 192 PET filaments
about 30-450 Denier (D) were gathered to form yarns.
[0081] 1.5 Yarns Composed of Low Melting Point Copolyester
Fibers
[0082] In this example, a total number of 16 to 192 low melting
point copolyester filaments about 30-450 Denier (D) were gathered
to form yarns.
Example 2 Thermo-Shapeable Fabrics and Articles Made by Embroidery
and Heat-Activation
[0083] In this example, one or more yarns (e.g., yarns of example
1) were strategically stitched onto a conventional base fabric to
create 2D patterns (e.g., grid pattern), which were then
heat-activated to produce thermo-shaped 3D articles directly out
from the engineered 2D pattern. Embroidery was made by use of
6-heads embroidery machine or embroidery machine with cording
device.
[0084] 2.1 Thermo-Shapeable Fabric Made by 6-Heads Embroidery
Machine
[0085] In this example, multiple layers of Tatami stitching at
different directions (i.e., 0.degree., 45.degree., and 90.degree.
to enhance yarn strength) using yarns of examples 1 were stitched
on a piece of base fabric. Detail conditions are summarized in
Table 1. A fabric carrying the embroidered 2D-grid pattern via
6-heads embroidery machine is illustrated in FIG. 5.
TABLE-US-00001 TABLE 1 Conditions for making embroidery via 6-heads
embroidery machine Embroidery via 6-heads embroidery machine Yarns
Untwisted core-sheath composite yarns Core: PET; sheath: low
melting point copolyester Yarns of example 1.1 Core: PET; sheath:
low melting point copolyester; cable type, double pli Untwisted
core-sheath composite yarn Core: PET; sheath: low melting point
copolyester Yarns of example 1.2 Stitching multiple layers of
Tatami stitching at different directions (i.e., 0.degree.,
45.degree., and 90.degree.) Density 600-700 SPM (stitches per min)
Bottom yarn PET fibers interlining Recycled PES Base fabric 100%
recycled PET Fabric made of core-sheath composited yarns about 40D
to 250D, pre-engineered pattern Non-woven fabric composed of two
temperatures fibers
[0086] 2.2 T Thermo-Shapeable Fabric Made by Embroidery Machine
with Cording Device
[0087] In this example, a pre-engineered pattern was embroidered on
a piece of base fabric using twisting yarns of example 1 with the
aid of the embroidery machine with cording device. Detail
conditions are summarized in Table 2. A fabric carrying embroidered
pattern via embroidery machine with cording device is illustrated
in FIG. 6.
TABLE-US-00002 TABLE 2 Conditions for making embroidery via
embroidery machine with cording device Embroidery via embroidery
machine with cording device Yarns Yarns of example 1.3, double
covered yarns about 1,800D Double covered yarns about 450D Core
fibers: PES about 300D Twisting fibers: 2 strands of low melting
point copolyester filaments Stitching Bottom yarn PET fibers Base
fabric 100% recycled PET Fabric made of core-sheath composited
yarns about 40D to 250D, pre-engineered pattern Non-woven fabric
composed of two temperatures fibers
[0088] 2.3 Articles Made by Thermo-Shapeable Fabrics of Examples
2.1 and 2.2
[0089] The fabric of examples 2.1 and 2.2 were respectively subject
to sublimation printing or heat press, in which the respective
embroideries created on the fabrics became harden upon contacting
with heat, while the rest of the fabric (i.e., parts that were
devoid of the embroidery) remained soft, thereby producing
thermo-shaped articles directly out from the embroidered pattern on
the fabric. Heat activation conditions used in this example are
summarized in Tables 3 and 4. A thermo-shaped article created by
heat-pressing the pattern embroidered on the fabric of example 2.1
is depicted in FIG. 7.
TABLE-US-00003 TABLE 3 Conditions for embroidery via 6-heads
embroidery machine Sublimation Printing Overall printing
120-210.degree. C., 25-120 sec Sporadic pattern 120-210.degree. C.,
25-120 sec 3-D metal mould 120-210.degree. C., 35-60 sec
TABLE-US-00004 TABLE 4 Heat activation conditions for heat-press
Heat Press Flat calendar 180-210.degree. C., 120-240 sec 3D-thermo
shaping Metal mould 130-230.degree. C., 120-300 sec Wood mould
130-230.degree. C., 120-300 sec
Example 3 Thermo-Shapeable Fabrics and Articles Made by Knitting
and Heat-Activation
[0090] In this example, one or more yarns of example 1 were
strategically knitted into a conventional fabric (e.g., fabric made
of PES) to create zones having different melting temperatures on
the fabric, accordingly, zones composed of low temperature fibers
were thermo-shapeable, and became harden after heat activation,
thereby creating thermo-shaped articles directly out from the
fabric. Knitting techniques used in this examples included
seamless, Jacquard, and Double Jacquard. Conditions of each
knitting techniques and subsequent heat activation are summarized
in Tables 5, 6 and 7. Fabrics produced by Jacquard knitting and
articles made therefrom are illustrated in FIGS. 8 to 12.
[0091] A fabric produced by Jacquard knitting is depicted in FIG.
8A, on which the parallel straight lines and lines that defined the
various diamond shapes on the fabric were composed by yarns having
relatively high melting point (e.g., yarns of example 1), and the
rest of the area were composed of yarns having relatively low
melting temperature (i.e., low melting point copolyester fibers).
The parts of the fabric made up by yarns having low melting points
melt and eventually harden after coming into contact with heat,
whereas the parts of the fabric made up by yarns having high
melting point would stay soft after heat-activation, thereby
allowing the fabric to comprise soft and hard areas, and can be
folded into pre-engineered shape (FIG. 8B).
[0092] Multiple layers of fabrics as that of FIG. 8 were stacked
and heated using a rectangular mold, thus creating a hardened
rectangular article as depicted in FIG. 9. By similar manner, a
triglide buckle created from a thermo-shapeable fabric produced by
Jacquard knit is depicted in FIG. 10. A thermo-shaped rectangular
article created from a thermo-shapeable fabric produced by Double
Jacquard knit is depicted in FIG. 11. FIG. 12 is a photograph
illustrating two sides of a thermo-shapeable fabric having similar
pattern as that depicted in FIG. 8A, in which the front of the
fabric is in blue color, while the back of the fabric is in
white.
TABLE-US-00005 TABLE 5 Condition for seamless knitting and heat
activation Seamless knitting Yarns Yarns of Example 1.1 low melting
point copolyester filaments Core-sheath composite filaments Core:
low melting point copolyester, sheath: PET Heat activation Vertical
steam heat, satin machine, 3 parts metal mould
TABLE-US-00006 TABLE 6 Condition for Jacquard knitting and heat
activation Jacquard knitting Yarns Yarns of Example 1.1 low melting
point copolyester Core-sheath composite filaments Core: PET,
sheath: low melting point copolyester Stitching Single Jersey Heat
activation Sublimation printing Roll 130-210.degree. C., 25-120 sec
Flat 120-210.degree. C., 25-120 sec Heat Press Flat calendar
195-210.degree. C., 10-240 sec Roll calendar 195-210.degree. C.,
10-240 sec 3D-thermo shaping Via metal module, 10-120 sec Via
wooden module, 10-240 sec Oven Dry oven 130-230.degree. C. Steam
oven 130-230.degree. C.
TABLE-US-00007 TABLE 7 Condition for Double Jacquard knitting and
heat activation Jacquard knitting Yarns Yarns of Example 1.1 low
melting point copolyester filaments Core-sheath composite filaments
Core: PET, sheath: low melting point copolyester Yarns of example
1.3, single covered yarns of 1800D Stitching quilting double
jacquard knit, birdseye Jacquard, single jacquard knit Heat
activation Heat Press Flat calendar 195-210.degree. C. Roll
calendar 195-210.degree. C. 3D-thermo shaping Metal mould Wooden
mould
Example 4 Thermo-Shapeable Fabrics and Articles Made by Woven and
Heat-Activation
[0093] Similar to procedures described in example 3, except weaving
technique was used in this example to create thermo-shapeable
fabric. Weaving techniques used in this examples included double
sided woven, Jacquard, dobby woven and Fil-coupe. Conditions of
each weaving techniques are summarized in Tables 8, 9 and 10; and
conditions for heat activation are provided in Tables 11.
TABLE-US-00008 TABLE 8 Condition for Double sided woven Double
sided woven Yarns Core-sheath composite yarns Core: PET, sheath:
low melting point copolyester Yarns of Example 1.1 low melting
point copolyester yarns Yarns of example 1.3, single covered yarns
of 1800D Stitching Low melting point yarns on one side, and high
melting point yarns (e.g., PET yarns) on the other side
TABLE-US-00009 TABLE 9 Condition for Jacquard woven Jacquard woven
Yarns Core-sheath composite yarns Core: PET, sheath: low melting
point copolyester Yarns of Example 1.1 low melting point
copolyester yarns Yarns of example 1.3, single covered yarns of
1800D Stitching Low melting point yarns Jacquard pattern
TABLE-US-00010 TABLE 10 Condition for Fil-coupe woven Fil-coupe
woven Yarns Core-sheath composite yarns Core: PET, sheath: low
melting point copolyester Yarns of Example 1.1 low melting point
copolyester yarns Yarns of example 1.3, single covered yarns of
1800D Stitching Jacquard weave structure Floating low melting point
yarns were shaved on the back of the fabric after weaving
TABLE-US-00011 TABLE 11 Conditions for heat activation Sublimation
Printing Overall printing 120-210.degree. C., 25-120 sec 3-D metal
mould 120-210.degree. C., 35-60 sec Heat Press Flat calendar
135-210.degree. C. Roll calendar 135-210.degree. C. 3D-thermo
shaping Via metal or wooden mould
[0094] It will be understood that the above description of
embodiments is given by way of example only and that various
modifications may be made by those with ordinary skill in the art.
The above specification, examples, and data provide a complete
description of the structure and use of exemplary embodiments of
the invention. Although various embodiments of the invention have
been described above with a certain degree of particularity, or
with reference to one or more individual embodiments, those with
ordinary skill in the art could make numerous alterations to the
disclosed embodiments without departing from the spirit or scope of
this invention.
* * * * *