U.S. patent application number 16/616716 was filed with the patent office on 2021-06-10 for textile product and production method thereof.
The applicant listed for this patent is OKAMOTO CORPORATION. Invention is credited to Kanako ANDO, Masahiko KONDO, Osamu ONISHI.
Application Number | 20210172096 16/616716 |
Document ID | / |
Family ID | 1000005413129 |
Filed Date | 2021-06-10 |
United States Patent
Application |
20210172096 |
Kind Code |
A1 |
KONDO; Masahiko ; et
al. |
June 10, 2021 |
TEXTILE PRODUCT AND PRODUCTION METHOD THEREOF
Abstract
The present invention provides a textile product and a method of
manufacturing thereof, the textile product being applicable also to
a target product having a complicated shape because an
electric/electronic function is given to the textile product. The
present invention is a textile product manufactured by using a
knitted or woven fabric, wherein the knitted or woven fabric
comprises a knitted or woven filamentous electronic-function member
in at least part of the knitted or woven fabric, wherein the
electronic-function member comprises a core portion comprising at
least two metal wires, an insulating layer that covers the at least
two metal wires so as to expose part of the at least two metal
wires, and an electronic-function portion electrically conducted to
each of the at least two metal wires and a sheath portion
comprising a knitted fabric that covers the core portion, and
wherein a yarn containing thermoplastic resin is included in at
least part of the knitted fabric of the electronic-function member,
and/or the yarn containing thermoplastic resin is interwoven with
the electronic-function member.
Inventors: |
KONDO; Masahiko;
(Nagaokakyo-shi, Kyoto-fu, JP) ; ONISHI; Osamu;
(Kitakatsuragi-gun, Nara, JP) ; ANDO; Kanako;
(Kitakatsuragi-gun, Nara, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OKAMOTO CORPORATION |
Kitakatsuragi-gun, Nara |
|
JP |
|
|
Family ID: |
1000005413129 |
Appl. No.: |
16/616716 |
Filed: |
December 19, 2017 |
PCT Filed: |
December 19, 2017 |
PCT NO: |
PCT/JP2017/045571 |
371 Date: |
November 25, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 1/12 20130101; D03D
15/593 20210101; D10B 2401/16 20130101; D04B 1/225 20130101; D03D
1/0088 20130101; D10B 2401/18 20130101; D10B 2403/02431 20130101;
D03D 15/497 20210101 |
International
Class: |
D03D 1/00 20060101
D03D001/00; D03D 15/40 20060101 D03D015/40; D03D 15/593 20060101
D03D015/593; D04B 1/12 20060101 D04B001/12; D04B 1/22 20060101
D04B001/22 |
Foreign Application Data
Date |
Code |
Application Number |
May 26, 2017 |
JP |
2017-104834 |
Claims
1. A textile product manufactured by using a knitted or woven
fabric, wherein the knitted or woven fabric comprises a knitted or
woven filamentous electronic-function member in at least part of
the knitted or woven fabric, wherein the electronic-function member
comprises a core portion comprising at least two metal wires, an
insulating layer that covers the at least two metal wires so as to
expose part of the at least two metal wires, and an
electronic-function portion electrically conducted to each of the
at least two metal wires and a sheath portion comprising a knitted
fabric that covers the core portion, and wherein a yarn containing
thermoplastic resin is included in at least part of the knitted
fabric of the electronic-function member, and/or the yarn
containing thermoplastic resin is interwoven with the
electronic-function member.
2. A textile product manufactured by using a knitted or woven
fabric, wherein, the knitted or woven fabric comprises a knitted or
woven filamentous electronic-function member in at least part of
the knitted or woven fabric, wherein the electronic-function member
comprises a core portion including at least two metal wires, an
insulating layer that covers the at least two metal wires so as to
expose part of the at least two metal wires, and an
electronic-function portion electrically conducted to each of the
at least two metal wires and a sheath portion including a knitted
fabric that covers the core portion, and wherein at least part of
the knitted fabric of the electronic-function member and/or at
least part around the electronic-function member contains
solidified thermoplastic resin.
3. The textile product according to claim 1, wherein the core
portion is sealed from outside in a region where the core portion
is covered by the knitted fabric.
4. The textile product according to claim 1, wherein the sheath
portion comprises a first covering portion that is made from the
knitted fabric and is provided on a side of the core portion and a
second covering portion that covers at least part of the first
covering portion and presses the first covering portion to the core
portion.
5. The textile product according to claim 4, wherein the second
covering portion is a long member helically wound around the first
covering portion.
6. The textile product according to claim 1, wherein the
electronic-function portion is selected from the group consisting
of a chip component, an electronic-function-substance containing
film, a battery, an input element, a display element, a sensor, an
antenna, a composite element thereof, and an integrated circuit
thereof.
7. The textile product according to claim 1, wherein the core
portion comprises a plurality of the electronic-function portions,
and wherein the plurality of electronic-function portions form a
circuit by being connected to each other with the at least two
metal wires.
8. The textile product according to claim 7, wherein the circuit
comprises sensor portions as the electronic-function portions.
9. The textile product according to claim 8, wherein the circuit
further comprises, as the electronic-function portions, a control
portion that controls operation of the sensor portions, a
communication portion that outputs information from the sensor
portions to outside, and a power supply portion that supplies power
to the sensor portions, the control portion, and the communication
portion.
10. A method of manufacturing the textile product according to
claim 1, the method comprising: a step of manufacturing a knitted
or woven fabric at least part of which is interwoven with the
electronic-function member, wherein the step comprises interweaving
the electronic-function member including the yarn containing
thermoplastic resin into at least part of the knitted fabric and/or
interweaving the electronic-function member and the yarn containing
thermoplastic resin in at least part of a region of the knitted or
woven fabric.
11. A method of manufacturing the textile product according to
claim 2, the method comprising: a step of manufacturing a knitted
or woven fabric at least part of which is interwoven with the
electronic-function member, the step comprising interweaving the
electronic-function member including the yarn containing
thermoplastic resin in at least part of the knitted fabric and/or
interweaving the electronic-function member and the yarn containing
thermoplastic resin in at least part of a region of the knitted or
woven fabric; and a step of melting and solidifying the yarn
containing thermoplastic resin interwoven into the knitted or woven
fabric.
12. The textile product according to claim 2, wherein the core
portion is sealed from outside in a region where the core portion
is covered by the knitted fabric.
13. The textile product according to claim 2, wherein the sheath
portion comprises a first covering portion that is made from the
knitted fabric and is provided on a side of the core portion and a
second covering portion that covers at least part of the first
covering portion and presses the first covering portion to the core
portion.
14. The textile product according to claim 13, wherein the second
covering portion is a long member helically wound around the first
covering portion.
15. The textile product according to claim 2, wherein the
electronic-function portion is selected from the group consisting
of a chip component, an electronic-function-substance containing
film, a battery, an input element, a display element, a sensor, an
antenna, a composite element thereof, and an integrated circuit
thereof.
16. The textile product according to claim 2, wherein the core
portion comprises a plurality of the electronic-function portions,
and wherein the plurality of electronic-function portions form a
circuit by being connected to each other with the at least two
metal wires.
17. The textile product according to claim 16, wherein the circuit
comprises sensor portions as the electronic-function portions.
18. The textile product according to claim 17, wherein the circuit
further comprises, as the electronic-function portions, a control
portion that controls operation of the sensor portions, a
communication portion that outputs information from the sensor
portions to outside, and a power supply portion that supplies power
to the sensor portions, the control portion, and the communication
portion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is the U.S. national stage of application No.
PCT/JP2017/045571, filed on Dec. 19, 2017. Priority under 35 U.S.C.
.sctn. 119(a) and 35 U.S.C. .sctn. 365(b) is claimed from Japanese
Patent Application No. 2017-104834, filed May 26, 2017; the
disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a textile product and a
method of manufacturing thereof, and specifically relates to a
textile product having an electric/electronic function and a method
of manufacturing thereof.
BACKGROUND ART
[0003] Conventionally, various sensors such as a vibration sensor,
a temperature sensor, and a pressure sensor have been attached to
industrial equipment for the purpose of detecting abnormality of
the industrial equipment. In order to achieve the above purpose,
for example, a packaged rectangular sensor (for example, Patent
Literature 1) is used for industrial equipment serving as a
measurement target (hereinafter, referred to as "target
product").
[0004] However, the packaged rectangular sensor can be disposed in
a case where the target product has a flat portion, but, in a case
where the target product has a complicated shape such as a curved
surface, the sensor cannot be easily attached to the target
product. Thus, it is problematic in that measurement is
difficult.
CITATION LIST
[0005] Patent Literature 1: JP 2008-03087 A
SUMMARY OF INVENTION
Technical Problem
[0006] In a case where the sensor can also be attached to a target
product having a complicated shape, it is possible to easily
measure vibration, temperature, pressure, and the like, regardless
of a shape of the target product. It is also possible to give an
electric/electronic function including not only a sensor function
but also a control function such as temperature control and a
communication function.
[0007] The inventors of the present invention have focused on a
stretchable textile product and have intended to provide a textile
product and a method of manufacturing thereof, the textile product
being applicable also to a target product having a complicated
shape because an electric/electronic function is given to the
textile product.
Solution to Problem
[0008] In order to achieve the above-mentioned object, a textile
product according to a first aspect of the present invention is a
textile product manufactured by using a knitted or woven fabric, in
which: the knitted or woven fabric comprises a knitted or woven
filamentous electronic-function member in at least part of the
knitted or woven fabric; the electronic-function member comprises a
core portion including at least two metal wires, an insulating
layer that covers the at least two metal wires so as to expose part
of the at least two metal wires, and an electronic-function portion
electrically conducted to each of the at least two metal wires and
a sheath portion including a knitted fabric that covers the core
portion; and a yarn containing thermoplastic resin is included in
at least part of the knitted fabric of the electronic-function
member, and/or the yarn containing thermoplastic resin is
interwoven with the electronic-function member.
[0009] According to the above-mentioned first aspect, the
thermoplastic resin existing in the vicinity of the
electronic-function member can be melted and solidified by heating
a region including the electronic-function member. With this
configuration, it is possible to form the region including the
electronic-function member in accordance with a shape of the target
product. This makes it possible to easily attach the
electronic-function member also to a target product having a
complicated shape.
[0010] Further, a textile product according to a second aspect of
the present invention is a textile product manufactured by using a
knitted or woven fabric, in which: the knitted or woven fabric
comprises a knitted or woven filamentous electronic-function member
in at least part of the knitted or woven fabric;
the electronic-function member includes a core portion including at
least two metal wires, an insulating layer that covers the at least
two metal wires so as to expose part of the at least two metal
wires, and an electronic-function portion electrically conducted to
each of the at least two metal wires and a sheath portion including
a knitted fabric that covers the core portion; and at least part of
the knitted fabric of the electronic-function member and/or at
least part around the electronic-function member contains
solidified thermoplastic resin.
[0011] According to the above-mentioned second aspect, it is
possible to form the region including the electronic-function
member in accordance with the shape of the target product. This
makes it possible to easily attach the electronic-function member
also to a target product having a complicated shape.
[0012] Further, in the textile product according to a third aspect
of the present invention, the core portion is sealed from outside
in a region in which the core portion is covered by the knitted
fabric.
[0013] According to the above-mentioned third aspect, it is
possible to improve water resistance of the sheath portion of the
electronic-function member.
[0014] Further, in the textile product according to a fourth aspect
of the present invention, the sheath portion includes a first
covering portion that is made from the knitted fabric and is
provided on a side of the core portion and a second covering
portion that covers at least part of the first covering portion and
presses the first covering portion to the core portion.
[0015] According to the above-mentioned fourth aspect, it is
possible to further bring the first covering portion of the
electronic-function member into tight contact with the core
portion.
[0016] Further, in the textile product according to a fifth aspect
of the present invention, the second covering portion is a long
member helically wound around the first covering portion.
[0017] According to the above-mentioned fifth aspect, in the
electronic-function member, it is possible to bring the first
covering portion into tight contact with the core portion, without
damaging the core portion.
[0018] Further, in the textile product according to a sixth aspect
of the present invention, the electronic-function portion is
selected from the group consisting of a chip component, an
electronic-function-substance containing film, a battery, an input
element, a display element, a sensor, an antenna, a composite
element thereof, and an integrated circuit thereof.
[0019] According to the above-mentioned sixth aspect, it is
possible to further reduce size and thickness of the
electronic-function member to be mounted. This makes it possible to
further thin the electronic-function member.
[0020] Further, in the textile product according to a seventh
aspect of the present invention, the core portion includes a
plurality of the electronic-function portions, and the plurality of
electronic-function portions form a circuit by being connected to
each other with the at least two metal wires.
[0021] According to the above-mentioned seventh aspect, it is
possible to further reduce the size of the electronic-function
member by using a circuit, instead of a component such as a
chip.
[0022] Further, in the textile product according to an eighth
aspect of the present invention, the circuit includes sensor
portions as the electronic-function portions.
[0023] According to the above-mentioned eighth aspect, it is
possible to use the electronic-function member as measuring
tools.
[0024] Further, in the textile product according to a ninth aspect
of the present invention, the circuit further includes, as the
electronic-function portions, a control portion that controls
operation of the sensor portions, a communication portion that
outputs information from the sensor portions to outside, and a
power supply portion that supplies power to the sensor portions,
the control portion, and the communication portion.
[0025] According to the above-mentioned ninth aspect, it is
possible to further reduce the size of the electronic-function
member serving as measuring tools.
[0026] Further, an invention according to a tenth aspect of the
present invention provides a method of manufacturing the textile
product according to the first aspect, the method comprising a step
of manufacturing a knitted or woven fabric at least part of which
is interwoven with an electronic-function member, the step
comprising interweaving the electronic-function member including
the yarn containing thermoplastic resin in at least part of the
knitted fabric and/or interweaving the electronic-function member
and the yarn containing thermoplastic resin in at least part of a
region of the knitted or woven fabric.
[0027] According to the above-mentioned tenth aspect, it is
possible to provide a textile product having an electric/electronic
function, the textile product being a product in which a region
including the electronic-function member is formable in accordance
with the shape of the target product.
[0028] Further, an invention according to an eleventh aspect of the
present invention provides a method of manufacturing the textile
product according to the second aspect, the method comprising: a
step of manufacturing a knitted or woven fabric at least part of
which is interwoven with the electronic-function member, the step
including interweaving the electronic-function member including the
yarn containing thermoplastic resin in at least part of the knitted
fabric and/or interweaving the electronic-function member and the
thermoplastic resin filament in at least part of a region of the
knitted or woven fabric; and a step of melting and solidifying the
yarn containing thermoplastic resin interwoven into the knitted or
woven fabric.
[0029] According to the above-mentioned eleventh aspect, by melting
and solidifying the thermoplastic resin existing inside or in the
vicinity of the electronic-function member, it is possible to form
the region including the electronic-function member in accordance
with the shape of the target product. This makes it possible to
provide a textile product having an electric/electronic function
and being applicable also to a target product having a complicated
shape.
Advantageous Effect of Invention
[0030] According to the present invention, it is possible to
provide a textile product having an electric/electronic function
and being applicable also to a target product having a complicated
shape.
BRIEF DESCRIPTION OF DRAWINGS
[0031] FIG. 1 is a partial cutaway plan view showing an example of
a structure of an electronic-function member for use in a textile
product according to Embodiment 1 of the present invention.
[0032] FIG. 2 is a schematic vertical-sectional view of the
electronic-function member shown in FIG. 1.
[0033] FIG. 3 is a developed diagram showing an example of a
structure of knitted fabric for use in the electronic-function
member shown in FIG. 1.
[0034] FIG. 4A is a schematic plan view showing an example of a
structure of knitted goods for use in the textile product according
to Embodiment 1 of the present invention.
[0035] FIG. 4B is a schematic vertical-sectional view of the
electronic-function member shown in FIG. 4A.
[0036] FIG. 5A is a schematic plan view showing another example of
the structure of the knitted goods for use in the textile product
according to Embodiment 1 of the present invention.
[0037] FIG. 5B is a schematic vertical-sectional view of an
electronic-function member shown in FIG. 5A.
[0038] FIG. 6A is a schematic plan view showing another example of
the structure of the knitted goods for use in the textile product
according to Embodiment 1 of the present invention.
[0039] FIG. 6B is a schematic vertical-sectional view of an
electronic-function member shown in FIG. 6A.
[0040] FIG. 7 is a partial cutaway plan view showing an example of
a structure of an electronic-function member for use in a textile
product according to Embodiment 3 of the present invention.
[0041] FIG. 8 is a schematic vertical-sectional view of the
electronic-function member shown in FIG. 7.
[0042] FIG. 9 is a partial cutaway plan view showing an example of
a structure of an electronic-function member for use in a textile
product according to Embodiment 4 of the present invention.
[0043] FIG. 10 is a schematic vertical-sectional view of the
electronic-function member shown in FIG. 9.
[0044] FIG. 11 is a partial cutaway plan view showing an example of
a structure of an electronic-function member for use in a textile
product according to Embodiment 5 of the present invention.
[0045] FIG. 12 is a schematic vertical-sectional view of the
electronic-function member shown in FIG. 11.
[0046] FIG. 13 is a schematic diagram showing an example of a
structure of an electronic-function member for use in a textile
product of the present invention.
[0047] FIG. 14 is a block diagram showing an example of an internal
circuit of the electronic-function member for use in the textile
product according to Embodiment 5 of the present invention.
DESCRIPTION OF EMBODIMENT
[0048] Hereinafter, embodiments of the present invention will be
described in detail with reference to the drawings as
appropriate.
Embodiment 1
[0049] A textile product according to this embodiment is a textile
product manufactured by using a knitted or woven fabric, in which:
the knitted or woven fabric comprises a knitted or woven
filamentous electronic-function member in at least part of the
knitted or woven fabric; the electronic-function member comprises a
core portion including at least two metal wires, an insulating
layer that covers the at least two metal wires so as to expose part
of the at least two metal wires, and an electronic-function portion
electrically conducted to each of the at least two metal wires, and
a sheath portion including a knitted fabric that covers the core
portion; and a yarn containing thermoplastic resin is included in
at least part of the knitted fabric of the electronic-function
member, and/or the yarn containing thermoplastic resin is
interwoven with the electronic-function member.
[0050] The present invention provides the textile product
manufactured by using a knitted or woven fabric that is obtained by
weaving or knitting yarns of natural fibers, semisynthetic fibers,
or synthetic fibers. A shape, dimensions, thickness, and the like
thereof are not particularly limited.
[0051] (Electronic-Function Member)
[0052] FIG. 1 is a partial cutaway plan view of an
electronic-function member for use in this embodiment. FIG. 2 is a
vertical-sectional view taken along line II-II' of FIG. 1. An
electronic-function member 1 includes a core portion 5 and a sheath
portion 20 covering the core portion 5. The core portion 5 includes
a first insulation-covered metal wire 10 and a second
insulation-covered metal wire 11 extending in a longitudinal
direction thereof and an electronic-function portion 12
electrically conducted to each of the first and second
insulation-covered metal wires 10 and 11. Knitted fabric 21 is used
as the sheath portion 20. Further, a chip component is used as the
electronic-function portion 12.
[0053] As shown in FIG. 2, the first insulation-covered metal wire
10 includes a metal wire 10a covered by an insulating layer 10b,
and the second insulation-covered metal wire 11 includes a metal
wire 11a covered by an insulating layer 11b. Part of the insulating
layer 10b is removed, and a joining portion 16 is formed to be in
contact with the exposed metal wire 10a. Further, part of the
insulating layer 11b is removed, and a joining portion 17 is formed
to be in contact with the exposed metal wire 11a. The
electronic-function portion 12 has a rectangular shape and includes
a pair of external electrodes 12a and 12b serving as
electronic-function portions at both end portions. By connecting
the external electrode 12a to the joining portion 16 and connecting
the external electrode 12b to the joining portion 17, the
electronic-function portion 12 is electrically connected to the
metal wire 10a and the metal wire 11a. The electronic-function
portion 12 and the metal wires 10a and 11a, which are electrically
connected to each other as described above, are covered by the
knitted fabric 21. Note that the joining portions 16 and 17 may be
formed as a structure different from joining material by plating or
the like. However, in a case where the insulating layers 10b and
11b are thin, joining material such as solder or a conductive
adhesive can form the joining portions 16 and 17. Further, in a
region in which the core portion 5 is covered by the knitted fabric
21, the core portion 5 is sealed from the outside.
[0054] Copper wires and nickel wires can be used as the metal wires
forming the core portion. Copper wires are preferable. A diameter
of each metal wire is not particularly limited, as long as the
metal wire can be formed into knitted fabric. However, the diameter
is 1 .mu.m or more and 1 mm or less, and is preferably 1 .mu.m or
more and 0.5 mm or less. Further, the insulating layer prevents the
metal wires from being brought into direct contact with each other,
and polyurethane resin, acrylic resin, or a long insulating sheet
or tape can be used. In this embodiment, the insulating layer
exposes part of each metal wire in order to secure electrical
conduction with the electronic-function portion. Herein, the part
of the metal wire merely means "not the whole surface of the metal
wire", and an area of the part is not particularly limited.
[0055] Further, the electronic-function portion has a function of
an active element such as a transistor, a diode, or a Peltier
element and a function of a passive element such as a resistor, a
capacitor, an inductor, or a thermistor and can be selected from
the group consisting of a chip component, an
electronic-function-substance containing film, a battery, an input
element, a display element, a sensor, an antenna, a composite
element thereof, and an integrated circuit thereof.
[0056] The passive element may be a chip component or may be an
electronic-function-substance containing film, such as a thick film
resistor, a thin film resistor, a thin film capacitor, or a thin
film inductor. Further, the passive element may be organic
material, composite material, or paste material containing an
electronic-function substance. The electronic-function-substance
containing film can be formed by applying a solution containing
element material, for example, dielectric material to surfaces of
the plurality of metal wires by using a publicly-known thick-film
printing method such as spin coating or screen printing and
performing heat processing. Further, it is also possible to use an
electronic-function-substance containing film patterned by a thin
film process. In that case, for example, it is possible to use a
lift-off method, vapor deposition, spattering, or the like. In the
lift-off method, after a resist is applied to the surfaces of the
plurality of metal wires, the resist is patterned by lithography,
then a solution containing element material is applied, and the
resist is removed thereafter. This makes it possible to leave an
intended thin film pattern. Specific examples of the
electronic-function portion encompass an NTC thermistor, a PTC
thermistor, and a Peltier element. In a case where those elements
are used for clothing including the electronic-function member, for
example, the NTC thermistor is used, it is possible to measure
temperature of the clothing. Further, in a case where the PTC
thermistor is used, it is possible to warm the clothing.
Furthermore, in a case where the Peltier element is used, it is
possible to cool the clothing.
[0057] Further, the electronic-function portion includes a
plurality of terminal portions that exchange signals with an
external device. Specific examples of the terminal portions
encompass an external electrode, a terminal, and an electrode pad.
For example, in a case where two terminal portions are two
terminals, one terminal can be connected to one metal wire, and the
other terminal can be connected to the other metal wire.
[0058] The sheath portion includes knitted fabric covering the core
portion and can be formed as one or more covering portions
laminated on a periphery of the core portion. Although knitted
fabric can be used as any covering portion, it is preferable to use
knitted fabric as a first covering portion that is provided on a
side of the core portion and at least part of which is in contact
with the core portion. In this embodiment, there will be described
an example where the sheath portion includes only the first
covering portion made from knitted fabric.
[0059] FIG. 3 shows a developed diagram of the knitted fabric 21.
The knitted fabric 21 can be formed as tubular knitted fabric
covering a periphery of the core portion 5 by weft knitting using a
knitting yarn. Weft knitting is preferable because stitches thereof
are finer than those of warp knitting. Further, in weft knitting,
stitches are formed by wrapping the knitting yarn around the
vertical core portion, and thus the core portion can be fastened
comparatively strongly by the knitting yarn of the sheath portion.
This makes it possible to bring the sheath portion into tight
contact with the core portion.
[0060] In this embodiment, a yarn containing thermoplastic resin is
included in at least part of the knitted fabric of the
electronic-function member, and/or a yarn containing thermoplastic
resin is woven with the electronic-function member. By heating a
region including the electronic-function member, it is possible to
melt and solidify the thermoplastic resin existing in the vicinity
of the electronic-function member. With this configuration, it is
possible to form the region including the electronic-function
member in accordance with a shape of the target product. This makes
it possible to easily attach the electronic-function member also to
a target product having a complicated shape.
[0061] In a case of an electronic-function member in which the yarn
containing thermoplastic resin (hereinafter, also referred to as
"thermoplastic filament yarn") is included in the at least part of
the knitted fabric of the electronic-function member, for example,
the knitted fabric can be manufactured by using the thermoplastic
filament yarn as a knitting yarn of at least part of the knitted
fabric. Examples of thermoplastic resin encompass polyurethane
resin, polyethylene resin, polyester resin, polyamide resin, and
polypropylene resin. It is preferable to use a thermoplastic
synthetic filament yarn made from thermoplastic resin such as
polyethylene resin, polyester resin, polyamide resin, and
polypropylene resin. Further, the thickness of the knitting yarn is
preferably 33 dtex or more and 250 dtex or less. In a case where
the thickness is less than 33 dtex, the core portion is not
sufficiently covered by the knitted fabric. Meanwhile, in a case
where the thickness is more than 250 dtex, it is difficult to knit
the knitted fabric by using a knitting machine because the knitting
yarn is too thick. It is also possible to use a plurality of
thermoplastic filament yarns made from thermoplastic resins having
different melting points or a composite filament yarn including a
thermoplastic filament yarn, a non-thermoplastic yarn, and other
yarns.
[0062] Also in a case where the thermoplastic filament yarn is
woven with the electronic-function member, it is possible to weave
or knit the knitted fabric by using the similar thermoplastic
filament yarn.
[0063] Further, the number of stitches in a single course of the
knitted fabric is not particularly limited, but is preferably two
or more and eight or less. A diameter of the tubular knitted fabric
can be reduced, and thus it is possible to further improve the
tight contact of the knitted fabric to the core portion.
[0064] Further, the number of stitches per natural length of 1 cm
in a single wale of the knitted fabric is not particularly limited,
but is preferably six or more and fourteen or less. Herein, the
term "natural length" means length of the knitted fabric to which
no tension or the like is given, i.e., length of the knitted fabric
that is naturally placed on a table as it is. In a case where the
number of stitches per natural length of 1 cm in a single wale of
the knitted fabric is six or more, it is possible to improve
coverage of the core portion with the knitted fabric. Further, in a
case where the number of stitches per natural length of 1 cm in a
single wale of the knitted fabric is fourteen or less, it is
possible to restrain a defect from occurring, the defect being
caused by a tuck defect of stitches of the knitted fabric because
the stitches are too fine.
[0065] In a case where the thermoplastic filament yarn is used as a
knitting yarn of the knitted fabric, the thermoplastic filament
yarn existing in the vicinity of the electronic-function member is
melted and solidified as described above. This makes it possible
not only to form a region including the electronic-function member
in accordance with the shape of the target product but also to
obtain the following effects. Specifically, heating and melting the
thermoplastic filament yarn included in the knitted fabric improves
the coverage of the core portion with the cooled and solidified
knitted fabric and the tight contact of the cooled and solidified
knitted fabric to the core portion. This makes it possible to
protect the electronic-function member and the metal wires from
moisture at the time of washing or sweating. Further, by heating
the thermoplastic filament yarn while applying pressure thereto, it
is possible to further improve the tight contact between the core
portion and the sheath portion. In a case where a composite
filament including a plurality of thermoplastic filament yarns
having different melting points is used as a knitting yarn, the
composite filament is heated at temperature that is higher than a
melting point of a thermoplastic filament yarn having a low melting
point but is lower than a melting point of a thermoplastic filament
yarn having a high melting point. Thus, the thermoplastic filament
yarn having the high melting point maintains a state of the knitted
fabric, and only the thermoplastic filament yarn having the low
melting point is melted. This makes it possible to improve
durability.
[0066] Further, the electronic-function member can be manufactured
by using, for example, the following method. Specifically, the
method includes: a step of forming a core portion including at
least two metal wires, an insulating layer that covers the at least
two metal wires so as to expose part of the at least two metal
wires, and an electronic-function portion electrically conducted to
each of the at least two metal wires; and a step of forming a
sheath portion that covers the core portion, in which the step of
forming the sheath portion includes at least a step of knitting
knitted fabric around the core portion by weft knitting and
covering the core portion.
[0067] The step of forming the core portion can further include: a
step of forming a conductive pattern on a plurality of metal wires;
and a step of mounting at least one electronic-function portion on
the plurality of metal wires. In a case where, for example, two
metal wires are used, as shown in FIG. 2, part of the insulating
layer on a surface of each metal wire is removed to expose a
surface of the metal wire, and a joining portion to which a
conductive pattern is given is formed. The number of conductive
patterns can be selected in accordance with the number of
input/output terminals of the electronic-function portion or the
number of electronic-function portions. Further, the conductive
pattern can have various shapes such as a line, a rectangle, a
circle, and a dot. In a case where the electronic-function portion
is mounted on a plurality of metal wires, it is preferable, in view
of stretchiness and durability, that the electronic-function
portion be mounted on the plurality of metal wires parallel to each
other in a direction perpendicular to a longitudinal direction of
the plurality of metal wires. Further, in a case where a plurality
of electronic-function portions are mounted in the longitudinal
direction of the metal wires, it is possible to form a plurality of
conductive patterns at predetermined intervals in the longitudinal
direction of the metal wires. The conductive patterns can be formed
by a printing method using a conductive paste or an electroplating
method.
[0068] In the step of covering the core portion, tubular knitted
fabric covering the periphery of the core portion can be formed by
weft knitting using a knitting yarn by using a circular knitting
machine. The circular knitting machine can be a publicly-known
circular knitting machine as disclosed in, for example, JP
S60-193993 U.
[0069] (Method of Manufacturing a Knitted or Woven Fabric)
[0070] A knitted or woven fabric for use in this embodiment can be
manufactured by supplying the electronic-function member to a
weaving machine and manufacturing a woven fabric or supplying the
electronic-function member to a knitting machine and manufacturing
knitted goods. Specifically, a method of manufacturing a knitted or
woven fabric for use in this embodiment comprises a step of
manufacturing a knitted or woven fabric at least part of which is
interwoven with the electronic-function member, and the step
comprises interweaving the electronic-function member including the
yarn containing thermoplastic resin in at least part of the knitted
fabric and/or interweaving the electronic-function member and the
yarn containing thermoplastic resin in at least part of a region of
the knitted or woven fabric.
[0071] Hereinafter, a case of a knitted fabric will be described.
An electronic-function member including a yarn containing
thermoplastic resin (thermoplastic filament yarn) as a knitting
yarn of knitted fabric is supplied alone to a knitting machine
(knitting method 1). Alternatively, an electronic-function member
including no thermoplastic filament yarn as a knitting yarn of
knitted fabric and one or more natural filament yarns,
semisynthetic filament yarns, synthetic filament yarns, or the like
including at least a thermoplastic filament yarn are combined and
are supplied to a knitting machine (knitting method 2).
Alternatively, an electronic-function member including a
thermoplastic filament yarn as a knitting yarn of knitted fabric
and one or more natural filament yarns, semisynthetic filament
yarns, and synthetic filament yarns including at least a
thermoplastic filament yarn are combined and are supplied to a
knitting machine (knitting method 3). A method of combining the
electronic-function member and a normal synthetic filament yarn is,
for example, supplying the electronic-function member and the
normal synthetic filament yarn from different yarn paths of face
yarns and forming knitted fabric or supplying the
electronic-function member and the normal synthetic filament yarn
from the same yarn path of a face yarn, arranging the
electronic-function member and the normal synthetic filament yarn
in parallel, and forming knitted fabric. The knitted fabric can be
formed by flat knitting, rib knitting, interlock knitting, pearl
knitting, pile knitting, or the like. Further, the
electronic-function member and the normal synthetic filament yarn
can be supplied from a yarn guide of a face yarn and a yarn path of
a back yarn, respectively, and can be subjected to plating
knitting. Further, in view of an economical point, the
electronic-function member can be interwoven only into a specific
necessary part by intarsia knitting (interlock knitting).
[0072] The knitting method 1 is a method of supplying the
electronic-function member including a thermoplastic filament yarn
as a knitting yarn of knitted fabric alone to a knitting machine.
However, a plating yarn and/or a back yarn can also be used as
necessary. In that case, a natural filament yarn, a semisynthetic
filament yarn, or a synthetic filament yarn including no
thermoplastic filament yarn can be used as the plating yarn and the
back yarn. With this configuration, at the time of heat processing,
it is possible to prevent a melted thermoplastic filament yarn from
falling.
[0073] Next, the knitting method 2 will be described. In the
knitting method 2, a plating yarn and/or a back yarn are/is used.
FIG. 4A is a schematic plan view showing an example of a structure
of knitted goods, and FIG. 4B is a schematic vertical-sectional
view of the knitted goods. Knitted goods 70A is knitted by using an
electronic-function member 71, a back yarn 72, and a plating yarn
73. The kind of yarn for use in knitted fabric forming a sheath
portion of the electronic-function member 71 is not particularly
limited and can be, for example, a natural filament yarn, a
semisynthetic filament yarn, or a synthetic filament yarn including
no thermoplastic filament yarn. Further, a natural filament yarn, a
semisynthetic filament yarn, or a synthetic filament yarn including
at least a thermoplastic filament yarn is used as the plating yarn
and the back yarn. In a case where one of the plating yarn and the
back yarn includes a thermoplastic filament yarn, the other yarn
can be omitted, or a non-melted filament yarn, for example, a
regenerated filament yarn such as rayon or a thermoplastic filament
yarn that is not melted at temperature at which the one of the
yarns is melted can be used as described below. Further, both the
plating yarn and the back yarn may include a thermoplastic filament
yarn.
[0074] In FIG. 4A and FIG. 4B, a thermoplastic filament yarn is
used as the plating yarn 73. The back yarn 72 has a function of, at
the time of heat processing of the knitted goods, preventing the
melted plating yarn 73 from falling and holding the melted plating
yarn 73. The plating yarn 73 is melted and solidified by the heat
processing, and thus rigidity is increased. By performing the heat
processing with respect to a region including the
electronic-function member in the knitted goods in accordance with
a predetermined mold so that the region matches with the shape of
the target product, it is possible to melt and solidify the region
and form the region in a predetermined shape.
[0075] FIG. 4A and FIG. 4B show an example where the plating yarn
73 is interwoven into the whole surface of the knitted goods 70A.
However, the plating yarn 73 may be interwoven only in a
predetermined region. Further, FIG. 4A and FIG. 4B show an example
where a thermoplastic filament yarn is used only as the plating
yarn 73. However, a thermoplastic filament yarn melted at a melting
point of the plating yarn 73 or less may also be used as the back
yarn 72. It is possible to form a plane resin region covering a
periphery of the electronic-function member.
[0076] FIG. 5A is a schematic plan view showing another example of
the structure of the knitted goods, and FIG. 5B is a schematic
vertical-sectional view of the knitted goods. Knitted goods 70B is
knitted, by moss stitch, by using a face yarn 74, the back yarn 72,
and the plating yarn 73 including a thermoplastic filament yarn. An
electronic-function member is used as the face yarn 74. By knitting
the knitted goods 70B by seed stitch, it is possible to interweave
the plating yarn 73 in a pattern. For example, in the knitted goods
70B, a region in which the electronic-function portion is to be
disposed is formed by interweaving the plating yarn 73 and the back
yarn 72, and the other parts are formed by interweaving the face
yarn 74 and the back yarn 72. Further, the face yarn 74 and the
plating yarn 73 seem to be cut at an end portion 74a and an end
portion 73a. However, in an actual knit structure, the face yarn
and the plating yarn are provided crosswise by a technique of
floating the face yarn and the plating yarn on a reverse side of
the knitted fabric, which is also referred to as "float stitch". In
other words, a part in which the face yarn 74 is woven and the
plating yarn 73 is caused to pass on the reverse side and a part in
which the plating yarn 73 is woven and the face yarn 74 is caused
to pass on the reverse side are disposed in a moss-stitch
shape.
[0077] Further, as shown in FIG. 5B, in a case where the knitted
goods 70B is formed by moss stitch, the plating yarn 73 is formed
in a mesh shape, and the knitted fabric and the plating yarn are
subjected to heat processing, it is possible to further restrain
the region including the electronic-function portion from being
easily folded or broken. Further, by using the transparent plating
yarn 73 containing no matting material and not using the back yarn
72 or using a transparent thermoplastic filament yarn containing no
matting material also as the back yarn 72, it is possible to cause
the region including the electronic-function portion to be
transparent.
[0078] FIG. 6A is a schematic plan view showing another example of
the structure of the knitted goods, and FIG. 6B is a schematic
vertical-sectional view of the woven fabric. Knitted goods 70C is
knitted, by cut-boss stitch, by using the face yarn 74, the back
yarn 72, and the plating yarn 73 including a thermoplastic filament
yarn. An electronic-function member is used as the face yarn 74. By
knitting the knitted goods 70C by cut-boss stitch, it is possible
to interweave the plating yarn 73 in a pattern. For example, in the
knitted goods 70C, a region in which the electronic-function
portion is to be disposed is formed by interweaving the plating
yarn 73 and the back yarn 72, and the other parts are formed by
interweaving the face yarn 74 and the back yarn 72. Further, the
face yarn 74 and the plating yarn 73 are cut in a part 75 where the
face yarn 74 and the plating yarn 73 overlap. This is different
from the case of moss stitch shown in FIG. 5A.
[0079] Next, the knitting method 3 will be described. In the
knitting method 3, an electronic-function member including a
thermoplastic filament yarn as a knitting yarn of knitted fabric, a
plating yarn, and/or a back yarn are used. A natural filament yarn,
a semisynthetic filament yarn, or a synthetic filament yarn
including at least a thermoplastic filament yarn is used as the
plating yarn and the back yarn. In a case where one of the plating
yarn and the back yarn includes a thermoplastic filament yarn, the
other yarn can be omitted, or a non-melted filament yarn, for
example, a regenerated filament yarn such as rayon or a
thermoplastic filament yarn that is not melted at temperature at
which the one of the yarns is melted can be used as described
below. Further, both the plating yarn and the back yarn may include
a thermoplastic filament yarn.
[0080] Further, the knitted or woven fabric can include at least
one power supply portion that is electrically connected to the
electronic-function portion. The electronic-function portion and
the power supply portion can be electrically connected by the metal
wires forming the core portion. Thus, it is unnecessary to
additionally provide a lead wire and connect the
electronic-function portion and the power supply portion. With this
configuration, it is possible to easily connect the
electronic-function portion and the power supply portion. An
external device that can be electrically connected to the
electronic-function portion is not limited to the power supply
portion and can be a signal generator, a transmitting device, a
receiving device, a detecting device, a measuring device, a display
device, an input device, or the like.
[0081] According to this embodiment, it is possible to provide a
textile product having an electric/electronic function and being
applicable also to a target product having a complicated shape.
Further, in the electronic-function member to which the
electric/electronic function is given, an external device such as a
power supply portion and the electronic-function portion can be
electrically connected by the metal wires forming the core portion.
This makes it possible to easily connect the external device and
the electronic-function portion.
Embodiment 2
[0082] A textile product according to this embodiment is a textile
product obtained by melting and solidifying thermoplastic resin
contained in the textile product according to Embodiment 1. The
textile product according to this embodiment is different from the
textile product according to Embodiment 1 in that at least part of
knitted fabric of an electronic-function member and/or at least
part around the electronic-function member contains solidified
thermoplastic resin.
[0083] In the textile product according to this embodiment, at
least part of the knitted fabric of the electronic-function member
and/or at least part around the electronic-function member contains
solidified thermoplastic resin, and, by melting and solidifying
thermoplastic resin, it is possible to form a region including the
electronic-function member in accordance with the shape of the
target product. Further, by fusing the solidified thermoplastic
resin to another knitting yarn, it is possible to integrate the
electronic-function member with a knitted or woven fabric. With
this configuration, even in a case where the knitted or woven
fabric is expanded or contracted, the electronic-function member
does not crack or peel off the knitted or woven fabric. Further, it
is possible to improve rigidity of a region in which the
electronic-function portion is disposed, increase strength thereof,
and reduce elongation thereof. This makes it possible to restrain
the region from being deformed and improve durability of the
electronic-function portion.
[0084] Hereinafter, a method of manufacturing thereof will be
described. A method of manufacturing the textile product according
to this embodiment, the method includes: a step of manufacturing a
knitted or woven fabric at least part of which is interwoven with
the electronic-function member, the step including interweaving the
electronic-function member including the yarn containing
thermoplastic resin in at least part of the knitted fabric and/or
interweaving the electronic-function member and the yarn containing
thermoplastic resin in at least part of a region of the knitted or
woven fabric; and a step of melting and solidifying the yarn
containing thermoplastic resin interwoven into the knitted or woven
fabric.
[0085] In this method, in a case where the electronic-function
member is interwoven with the yarn containing thermoplastic resin
(thermoplastic filament yarn), the thermoplastic filament yarn may
be a thermoplastic filament yarn having a melting point lower than
that of another knitting yarn or a thermoplastic filament yarn
having a melting point equivalent to that of another knitting yarn.
In a case where the thermoplastic filament yarn having the melting
point lower than that of another knitting yarn is used, it is
preferable to use a thermoplastic filament yarn having a melting
point that is lower by 30.degree. C. or more than a melting point
of another knitting yarn and is more preferably lower by 50.degree.
C. or more than the melting point.
[0086] Note that heating temperature for melting and solidifying
the thermoplastic filament yarn can be appropriately set in
accordance with a melting point of a thermoplastic filament yarn to
be used. However, it is necessary that the heating temperature do
not exceed an upper limit of heat resistant temperature of the
electronic-function portion included in the electronic-function
member.
[0087] Regarding a combination of knitting yarns, in the example of
FIG. 4A, the knitted goods is knitted by using a natural filament
yarn or a synthetic filament yarn having a comparatively high
melting point (a synthetic filament yarn having a melting point
higher than that of the thermoplastic filament yarn) as the sheath
portion of the electronic-function member and using a fiber having
a comparatively high melting point (a filament yarn having a
melting point higher than that of the thermoplastic filament yarn)
such as nylon or polyurethane as the back yarn. After knitting, by
heating only the region in which the electronic-function portion is
disposed or the whole surface of the knitted goods while applying
pressure to the region or the whole surface as necessary, only the
thermoplastic filament yarn having the lowest melting point is
melted and solidified.
[0088] Table 1 shows exemplary combinations of thermoplastic
filament yarns to be melted and serving as a knitting/weaving yarn
for use in a knitted or woven fabric and other knitting/weaving
yarns. Herein, non-melted fibers in Table 1 are fibers other than
thermoplastic fibers to be melted and indicate fibers for use in
the sheath portion of the electronic-function member or the back
yarn, and melted fibers indicate thermoplastic fibers to be
melted.
TABLE-US-00001 TABLE 1 Non-melted fibers Melted fibers Difference
in melting point Polyester fiber (Melting Nylon 6 fiber
Approximately 50 degrees point: 260.degree. C.) Polyvinyl chloride
fiber Approximately 50 degrees Vinylon fiber Approximately 30
degrees Polypropylene fiber Approximately 100 degrees Polyethylene
fiber Approximately 130 degrees Low-melting polyester fiber
Approximately 150 degrees Low-melting nylon fiber Approximately 150
degrees Polyurethane fiber Polypropylene fiber Approximately 50
degrees (Melting point: 230.degree. C.) Polyethylene fiber
Approximately 80 degrees Low-melting polyester fiber Approximately
100 degrees Nylon 6 fiber (Melting Polypropylene fiber
Approximately 50 degrees point: 215.degree. C.) Polyethylene fiber
Approximately 80 degrees Low-melting polyester fiber Approximately
100 degrees Low-melting nylon fiber Approximately 100 degrees
Cotton (Decomposition Polypropylene fiber Approximately 70 degrees
point: 235.degree. C.) Low-density polyethylene fiber Approximately
100 degrees Hemp (Decomposed at Polypropylene fiber Approximately
40 degrees 200.degree. C.) Polyethylene fiber Approximately 70
degrees Rayon (Decomposition Nylon 6 fiber Approximately 50 degrees
is started at 260.degree. C. Polyvinyl chloride fiber Approximately
50 degrees or more) Vinylon fiber Approximately 30 degrees
Polypropylene fiber Approximately 100 degrees Low-density
polyethylene fiber Approximately 130 degrees Low-melting polyester
fiber Approximately 150 degrees Low-melting nylon fiber
Approximately 150 degrees p-aramid resin Polyester fiber
Approximately 140 degrees (Carbonized at 400.degree. C. Nylon 6
fiber Approximately 190 degrees or more) Polyvinyl chloride fiber
Approximately 190 degrees Vinylon fiber Approximately 170
degrees
[0089] Combinations of the melted fibers and the non-melted fibers
are not limited to the range shown in Table 1, and melting points
of the non-melted fibers only need to be higher by 30.degree. C. or
more than melting points of the melted fibers.
Embodiment 3
[0090] A textile product in this embodiment has a configuration
similar to that of a textile product in Embodiment 1, except that
the sheath portion including a first covering portion that is made
from knitted fabric and is in contact with the core portion and a
second covering portion that covers at least part of the first
covering portion and presses the first covering portion to the core
portion is used as the electronic-function member.
[0091] FIG. 7 is a partial cutaway plan view of the
electronic-function member according to this embodiment, and FIG. 8
is a vertical-sectional view taken along line VIII-VIII' in FIG. 7.
Hereinafter, a part common to Embodiment 1 will not be described,
and only a different part will be described.
[0092] An electronic-function member 2 includes a core portion 5
and a sheath portion 20 covering the core portion 5. The sheath
portion 20 further includes a first covering portion 22 made from
knitted fabric and existing on a side of the core portion 5 and a
second covering portion 23 wound around the first covering portion
22. The second covering portion 23 presses the first covering
portion 22 to the core portion 5, thereby further bringing the
first covering portion 22 into tight contact with the core portion
5.
[0093] The second covering portion can be a long member. The long
member can be as follows: a natural filament yarn made from cotton,
hemp, wool, or the like; a semisynthetic filament yarn made from
cellulose or the like; a synthetic filament yarn made from nylon,
acryl, polyester, polyurethane, or the like; or a composite yarn, a
tape, a string, or the like obtained by combining a plurality of
fiber materials. By using the long member, it is possible to bring
the first covering portion into tight contact with the core
portion, without damaging the core portion. Further, in a case
where a synthetic filament yarn containing thermoplastic resin is
used as the first covering portion, a synthetic filament yarn
containing thermoplastic resin can also be used as the second
covering portion. By covering the first covering portion with the
second covering portion and thereafter heating and melting the
synthetic filament yarn, it is possible to further improve the
tight contact of the first covering portion to the core portion
after cooling.
[0094] Further, the following examples can also be used as a
combination of the first covering portion and the second covering
portion. For example, in a case where a synthetic filament yarn
containing thermoplastic resin is used as the first covering
portion, it is possible to use a yarn made from the above-mentioned
non-melted fiber (hereinafter, referred to as "non-melted filament
yarn") as the second covering portion. Further, it is possible to
use a non-melted filament yarn as the first covering portion and
use a synthetic filament yarn containing thermoplastic resin as the
second covering portion. Also in those cases, it is possible to
improve the tight contact of the first covering portion to the core
portion.
[0095] The electronic-function member for use in this embodiment
can be manufactured by using a method including a step of helically
winding the long member around the first covering portion after the
first covering portion is formed. By using a publicly-known sheath
yarn winding apparatus disclosed in, for example, JP S63-282304 A,
the second covering portion can be formed by drawing a string wound
around a bobbin while rotating the bobbin and winding the string
around the electronic-function member while moving, in an upward
direction or downward direction, the electronic-function member on
which the first covering portion has been formed. Note that winding
intervals of the second covering portion in a longitudinal
direction of the electronic-function member can be adjusted as
necessary. By reducing the winding intervals (or increasing the
number of times of winding), it is possible to further improve the
tight contact of the first covering portion to the core portion.
Further, it is also possible to further improve the tight contact
of the first covering portion to the core portion by increasing a
diameter of the yarn forming the second covering portion to reduce
the winding intervals.
[0096] According to this embodiment, in addition to the effect of
Embodiment 1, the following effects can be obtained by providing
the second covering portion: it is possible to further improve the
tight contact of the first covering portion to the core portion and
further improve durability of the electronic-function member.
[0097] Note that, although this embodiment shows an example where
the second covering portion is provided, it is also possible to
provide another covering portion as necessary. For example, the
second covering portion is helically wound in the longitudinal
direction of the electronic-function member, and, in addition, a
third covering portion can be wound around the second covering
portion in an opposite direction of a direction of the second
covering portion so as to cross the second covering portion. By
providing the third covering portion, it is possible to further
improve the tight contact of the first covering portion to the core
portion.
[0098] Further, a paralleled yarn including a synthetic filament
yarn containing thermoplastic resin may be provided between the
core portion and the first covering portion. Also in this case, it
is also possible to improve the tight contact of the first covering
portion to the core portion. In this case, combinations of the
first covering portion and the second covering portion can be as
follows: a case where synthetic filament yarns containing
thermoplastic resin are used as both the first covering portion and
the second covering portion; a case where non-melted filament yarns
are used as both the first covering portion and the second covering
portion; and a case where a synthetic filament yarn containing
thermoplastic resin is used as one of the first covering portion
and the second covering portion and a non-melted filament yarn is
used as the other.
Embodiment 4
[0099] A textile product according to this embodiment has a
configuration similar to that of the textile product in Embodiment
1, except that an electronic-function member including an
electronic-function-substance containing film is used as the
electronic-function portion, instead of a chip component.
[0100] FIG. 9 is a partial cutaway plan view of an
electronic-function member according to this embodiment, and FIG.
10 is a vertical-sectional view taken along line X-X' of FIG. 9.
Hereinafter, a part common to Embodiment 1 will not be described,
and only a different part will be described.
[0101] An electronic-function member 3 includes a core portion 6
and a sheath portion 20 covering the core portion 6. The core
portion 6 includes a first insulation-covered metal wire 10, a
second insulation-covered metal wire 11, and an electronic-function
portion 13 including an electronic-function-substance containing
film and provided to be electrically conducted to each of the first
and second insulation-covered metal wires 10 and 11.
[0102] As described above, the electronic-function-substance
containing film can be formed by applying a solution containing
element material, for example, dielectric material to surfaces of a
plurality of metal wires by using a publicly-known printing method
such as spin coating and performing heat processing. Further, it is
also possible to use a patterned thin film. Herein, the
electronic-function substance encompasses dielectric material,
conductive material, magnetic material, piezoelectric material,
semiconductor material, pyroelectric material, and the like.
[0103] According to this embodiment, in addition to the effect of
Embodiment 1, the following effects can be obtained by using the
electronic-function-substance containing film: size and thickness
of the electronic-function portion to be mounted on the metal wires
can be flexibly changed, and thus it is possible to provide a
textile product that can be optimally designed in accordance with
use of the electronic-function member.
Embodiment 5
[0104] A textile product according to this embodiment has a
configuration similar to that of the textile product in Embodiment
1, except that a long insulating member is used as the insulating
layer covering the metal wires and an electronic-function member
including an electronic-function-substance containing film formed
to cover a periphery of the plurality of metal wires in a strip
shape is used as the electronic-function portion, instead of a chip
component.
[0105] FIG. 11 is a partial cutaway plan view of an
electronic-function member according to this embodiment, and FIG.
12 is a vertical-sectional view taken along line XII-XII' of FIG.
11. An electronic-function member 4 includes a core portion 7 and a
sheath portion 20 covering the core portion 7. The core portion 7
includes: metal wires 10a and 11a extending in a longitudinal
direction and between which an insulating member 15 is interposed;
and an electronic-function-substance containing film 14 formed to
cover a periphery of the metal wires 10a and 11a in a strip shape
and provided to be electrically conductible to the metal wires 10a
and 11a. Knitted fabric 21 is used as the sheath portion 20.
[0106] An insulating member of the electronic-function member for
use in this embodiment can be a long insulating sheet interposed
between the metal wires, an insulating tape attached in the
longitudinal direction of the metal wires, an insulating layer
formed in the longitudinal direction of the metal wires, or the
like. The insulating layer can be made from polyurethane resin,
acrylic resin, or the like.
[0107] As described above, the electronic-function-substance
containing film can be formed by applying a solution containing
element material, for example, dielectric material to surfaces of a
plurality of metal wires by using a publicly-known printing method
such as spin coating and performing heat processing. Further, it is
also possible to use a patterned thin film element.
[0108] According to this embodiment, in addition to the effect of
Embodiment 1, the following effects can be obtained by using the
electronic-function-substance containing film: size and thickness
of the electronic-function portion to be mounted on the metal wires
can be flexibly changed, and thus it is possible to provide a
textile product that can be optimally designed in accordance with
use of the electronic-function member.
[0109] Examples of a single electronic-function portion have been
described in Embodiments 1 to 5. However, the electronic-function
member for use in the textile product of the present invention can
also include a plurality of electronic-function portions. For
example, the electronic-function member may include: a first
electronic-function portion provided to be electrically conductible
to each of at least two metal wires included in the first wiring
portion; and a second electronic-function portion different from
the first wiring portion and provided to be electrically
conductible to each of at least two metal wires included in a
second wiring portion. Similarly, the electronic-function member
may further include a third wiring portion and a third
electronic-function portion, a fourth wiring portion and a fourth
electronic-function portion, a fifth wiring portion and a fifth
electronic-function portion, and the like. The first
electronic-function portion may be different from the other
electronic-function portions, or all electronic-function portions
may be the same. For example, a temperature sensor element (for
example, NTC thermistor) is used as the first electronic-function
portion, and a heater element (for example, PTC thermistor) is used
as the second electronic-function portion.
[0110] FIG. 13 is a schematic diagram showing an example of a
structure of the above-mentioned electronic-function member
including the plurality of electronic-function portions, and the
sheath portion is not shown. A core portion 30 includes metal wires
31, 32, 33, 34, 35, and 36, each of which is covered by an
insulating layer. The two metal wires 31 and 32 form a first wiring
portion 37, the two metal wires 33 and 34 form a second wiring
portion 38, and the two metal wires 35 and 36 form a third wiring
portion 39. A first electronic-function portion 41 is joined to a
joining portion 31a obtained by exposing part of the metal wire 31
and a joining portion 32a obtained by exposing part of the metal
wire 32. Further, a second electronic-function portion 42 is joined
to a joining portion 33a obtained by exposing part of the metal
wire 33 and a joining portion 34a obtained by exposing part of the
metal wire 34. Further, a third electronic-function portion 43 is
joined to a joining portion 35a obtained by exposing part of the
metal wire 35 and a joining portion 36a obtained by exposing part
of the metal wire 36. Although FIG. 13 shows an example where six
metal wires are disposed in parallel, the six metal wires can also
be bundled while preventing the first to third electronic-function
portions from being brought into contact with each other.
[0111] Further, the electronic-function member for use in the
textile product of the present invention may form a circuit by
connecting a plurality of electronic-function portions to each
other with at least two metal wires. This form will be described in
more detail in the following Embodiment 6.
Embodiment 6
[0112] In an electronic-function member for use in a textile
product according to this embodiment, a core portion includes a
plurality of electronic-function portions, and the plurality of
electronic-function portions forms a circuit by being connected to
each other with at least two metal wires (hereinafter, the circuit
will also be referred to as "internal circuit"). FIG. 14 is a block
diagram showing an example of a configuration of the internal
circuit. A circuit 60 includes a plurality of circuit element
portions forming the circuit, and the circuit element portions
correspond to the electronic-function portions. The circuit 60
includes, as the circuit element portions, a passive element
portion 61, an active element portion 62, a control portion 63 that
controls operation of the passive element portion 61 and the active
element portion 62, a communication portion 64 that exchanges a
communication signal with the outside, a power supply portion 65
that supplies power to each portion, an A/D converter portion 66
that A/D-converts a data signal received from the passive element
portion 61 and outputs the converted data signal to the control
portion 63, a D/A converter portion 67 that D/A-converts a control
signal received from the control portion 63 and supplies the
converted control signal to the active element portion 62, a
transmitting/receiving antenna portion 68 that performs wireless
transmission/reception with respect to the outside, and a wireless
charging portion 69 that receives an electric wave for power from
the outside and outputs power generated from the electric wave for
power to the power supply portion 65. Further, the circuit 60
includes, as an external device, a display portion 70 that displays
predetermined image information received from the control portion
63.
[0113] The passive element portion 61 can be, for example, a sensor
as a passive element. In that case, the passive element portion
will also be referred to as "sensor portion". The sensor can be a
temperature sensor, an infrared sensor, a humidity sensor, a sound
sensor, an optical sensor, a magnetic sensor, a pressure sensor, an
acceleration sensor, a position sensor, or the like. Further, the
active element portion 62 can be, for example, a heater element or
an oscillating element as an active element. A combination of the
passive element and the active element can be variously selected in
accordance with use of the electronic-function member. For example,
it is possible to give a temperature adjusting function to the
electronic-function member by using a temperature sensor as the
passive element and a heater element as the active element.
Further, the power supply portion 65 can be, for example, a
capacitor or a secondary battery.
[0114] The plurality of electronic-function portions can be
connected to each other by, for example, disposing the plurality of
electronic-function portions in a longitudinal direction of the two
metal wires and electrically conducting the electronic-function
portions to the respective metal wires.
[0115] The electronic-function member for use in this embodiment
can also be formed as knitted goods by using a method similar to
the method described in Embodiment 1. That is, it is possible to
manufacture knitted goods by supplying the electronic-function
member including the internal circuit to a knitting machine and
using the electronic-function member as a normal yarn.
[0116] According to this embodiment, in addition to the effect of
Embodiment 1, the following effect can be obtained by using a
circuit, instead of a plurality of components such as chips: it is
possible to provide a textile product including a smaller
electronic-function member.
[0117] Note that, in this embodiment, circuit element portions
other than the passive element portion and the active element
portion can also be provided as external devices, instead of being
included in the electronic-function member. In that case, although
the external devices are held by the knitted goods, the circuit
element portions other than the passive element portion and the
active element portion and the external devices can be electrically
connected with the metal wires forming the core portion, as
described in Embodiment 1.
[0118] Further, the circuit element portions shown in FIG. 14 are
merely an example, and it is possible to use various circuit
element portions in accordance with use.
[0119] Hereinabove, embodiments of the present invention have been
described. However, a person skilled in the art can understand that
those embodiments are merely examples and various modification
examples can be made within the scope of the present invention. For
example, Embodiment 3 shows an example where a knitting yarn is
helically wound around the first covering portion as the second
covering portion. However, the second covering portion may be
formed by using knitted fabric or may be formed by employing
plating knitting.
INDUSTRIAL APPLICABILITY
[0120] According to the present invention, it is possible to
provide a textile product having an electric/electronic function
and being applicable also to a target product having a complicated
shape.
REFERENCE SIGNS LIST
[0121] 1, 2, 3, 4 electronic-function member [0122] 5, 6, 7 core
portion [0123] 10 first insulation-covered metal wire [0124] 11
second insulation-covered metal wire [0125] 10a, 11a metal wire
[0126] 10b, 11b insulating layer [0127] 12, 13, 14
electronic-function portion [0128] 12a, 12b external electrode
[0129] 15 insulating member [0130] 16, 17 joining portion [0131] 20
sheath portion [0132] 21 knitted fabric [0133] 22 first covering
portion [0134] 23 second covering portion [0135] 30 core portion
[0136] 31, 32, 33 metal wire [0137] 34, 35, 36 metal wire [0138]
31a, 32a, 33a joining portion [0139] 34a, 35a, 36a joining portion
[0140] 37 first wiring portion [0141] 38 second wiring portion
[0142] 39 third wiring portion [0143] 41 first electronic-function
portion [0144] 42 second electronic-function portion [0145] 43
third electronic-function portion [0146] 60 circuit [0147] 61
passive element portion [0148] 62 active element portion [0149] 63
control portion [0150] 64 communication portion [0151] 65 power
supply portion [0152] 66 A/D converter portion [0153] 67 D/A
converter portion [0154] 68 transmitting/receiving antenna portion
[0155] 69 wireless charging portion [0156] 70A, 70B, 70C knitted
goods [0157] 71 electronic-function member [0158] 72 back yarn
[0159] 73 plating yarn [0160] 73a end portion of plating yarn
[0161] 74 face yarn [0162] 74a end portion of face yarn [0163] 75
part in which face yarn and thermoplastic fiber overlap
* * * * *