EP2530195A1 - Knit or woven fabric, method and thread for producing same and use of same - Google Patents

Abstract

The knitted/woven fabric comprises non-meshed intermediate layer made of Jersey fabric which is inserted between upper and lower layers of fabric. The fabric is formed by knitting yarns in parallel after expansion of yarn. The expandable material of yarn is made of foaming agent such as hydrocarbon containing materials, which is encapsulated partially in hollow spheres such as Expancel 930MB120(RTM: thermoplastic hollow spheres) microspheres in mixture with ethylene vinyl acetate (EVA) of high and low viscosity. Independent claims are included for the following: (1) method for producing knitted fabric, which involves expanding yarn after sewing, gluing, molding of yarn by adjusting offset of the ambient conditions in solid state; and (2) braided or coated yarn for producing knitted fabric.

Description

The present invention relates to a knitted fabric or woven fabric, a method and yarn for its production and its use. Reference is made in particular to the preambles of claims 1, 5, 7, 13 and 15.

In particular, knit fabrics made from a novel yarn having multiple components are described. In addition, the method for producing the yarn, which is coated or coated, is shown.

Textile yarns exist in the prior art in many different structures, as well as their manufacturing processes and the ultimately produced knit fabrics having a variety of uses.

However, those skilled in the art are always challenged to provide new types and structures for knit fabrics or woven fabrics and their yarns which are achieved by altering their manufacturing parameters, composition and construction to meet certain requirement profiles. A versatile applicability is always desirable.

These objects and problems are solved in a surprising manner by the subject-matter of claims 1, 5, 7, 13 and 15, respectively.

In the first place, it is therefore of inventive significance that the mesh or woven fabric uses at least one yarn which has a coating or sheathing of expandable, in particular foamable, material. The knitted or woven fabric according to the invention may have this yarn in the already expanded state or may also contain an unexpanded yarn which is increased in volume only at a later time and in particular is subject to foaming. The desired increase in the volume or diameter of the yarn is controlled by temporarily changed environmental conditions. Conceivable changes in the external conditions are, for example, the temperature, the pressure, the humidity and / or the change in the state of aggregation of further present substances, which then cause foaming or swelling of the yarn coating or coating due to the change. Also, for example, a chemical reaction may be responsible for this. However, the soul of the yarn remains unaffected, as only the coating or sheathing undergoes spatial enlargement. The diameter of the yarn according to the invention can thus be increased to a multiple and in the range of 1,000% and more.

The clou is therefore to create or use a yarn or to create a textile in which a volume can be achieved with which the yarn can be obtained in a conventional machine for producing textiles, for example a knitted fabric. or weaving machine could not be processed. The yarn according to the invention can thus be processed with conventional machines and the volume of the yarn subsequently increased significantly. This opens up new applications and manufacturing possibilities.

At the same time, bonding of the actual textile and of the expanded volume, for example by fusion or gluing, can take place at the same time. In particular, textile layers can be connected to the expanded volume.

In this case, all the usual textiles, such as knitted or knitted or fabric can be produced. With particular advantage are spacer knit or composite fabric used in which the yarn according to the invention is arranged between two Taxtil layers. These layers can be knit or weaving connected. This is not necessary. By way of example, a connection can also be made by expanding such that the expanded volume establishes a connection to the textile layers.

The core of the invention is formed by a yarn or a method for producing such a yarn. It is known in principle to create and use coated yarns, but a yarn according to the invention has not been proven in the prior art.

The yarn of the invention comprises a core and a coating or sheath of expandable material which causes an increase in the overall diameter of the yarn due to temporarily adjustable external conditions. This means that in particular the casing performs an expansion, which then leads to an increase in the overall diameter of the yarn. It is not mandatory that this expansion leads in all directions to a uniform or equal expansion. The larger diameter is thus to be understood as an enlarged cross-sectional area or as an enlarged comprehensive overall diameter. At least, however, an increase in the size of the cross-sectional area is effected, whereby also such cross-sectional area areas are counted, which are taken for example by trapped gas bubbles. In particular, the increase is not reversible. In particular, it also remains at elimination of the environmental condition created for expansion. In particular, the volume is at least doubled, in particular the diameter at least doubled or the volume is quadrupled.

Such a yarn can be used in conventional machines for the production of textiles, knitted fabrics, and the like, and subsequently lead to an increase in the diameter of the yarn. This can be used for example to increase the density and / or thickness of the material to be produced. It is also conceivable, thereby a the separate structure of the individual yarns dissolving and leading to a closed filled volume increase the diameter of the yarns effect. In this case, the increase in the diameter is in particular not permitted the same in all directions in space, so that, in particular in juxtaposed yarns according to the invention such an expansion results, which leads to a fusion of the expanded volume.

Advantageously, after the increase in the diameter, in particular after restoring the original external conditions and / or establishing the conditions of use for the yarn or the material produced therefrom, the expanded volume becomes (again) a solid.

During the expansion, especially when it is caused by temperature increase, usually a consistency change of the sheath is effected. It will often be viscous or at least deformable so that they can expand or foam. Advantageously, after the expansion, a solid state of the expanded volume or of the expanded coating or sheathing is again caused. However, a solid state does not mean rigid and immobile or incompressible. Rather, preference is given to a state which, although a solid state, ensures mobility and compressibility.

In order to be able to ensure such an expansion, the expandable material according to claim 8 contains in particular at least one foaming agent and at least one foam wall former. The foaming agent causes an increase in the volume and secures the Schaumwandbildner the contours, both outer and inner, of the expanded volume. Suitable foaming agents are, in particular, materials containing hydrocarbon, since these are generally thermally activatable. This can be done by evaporation of hydrocarbon, especially in the form of CO ₂ . The at least one foam wall-forming agent contains in particular at least one polymer material, in which case a thermoplastic polymer material is chosen in particular since this becomes deformable upon thermal activation and upon lowering the temperature can be converted back to a solid state. In addition, a thermoplastic polymer material may also be used to form a bond to the surrounding textile, knit and / or fabric layers. In particular, the expandable material comprises at least one foaming agent and a foam wall former. Additional additions can be added to this. With particular advantage, the foaming agent is at least partially encapsulated, in particular in hollow spheres in the expandable material. In particular, thermoplastic hollow spheres are used. In such a case, the hollow spheres or their shell can be part of the foam wall former at the same time.

When using thermoplastic hollow spheres by thermal activation not only activation of the foaming agent or evaporation of hydrocarbons can be achieved, but it can also their spread by softening the thermoplastic hollow spheres and by making deformable the foam wall forming a reliable function of the yarn according to the invention in a simple Be realized manner.

Advantageously, the yarn according to claim 3 thermosplastic polymer materials as Schaumwandbildner and in thermoplastic hollow spheres forming microspheres, encapsulated hydrocarbon droplets. As the temperature increases, they begin to evaporate and lead to expansion of the microspheres. As a result, even without destroying the microspheres, an expansion can be ensured. Also, an independent curing, especially when lowering the temperature, possible.

Advantageously, the hydrocarbon droplets evaporate according to claim 10 at a temperature range of 170 ° -180 °. This is particularly favorable, since such temperatures are not reached in the manufacturing process, but the fabric or textile, the fabric or knitted fabric, however, usually do not damage either. Also, at such temperatures a particularly good deformability of thermoplastics can be ensured. Also, at such temperatures a particularly good connection between the actual textile or fabric or Fabric or knitted fabric and the foam wall formers, in particular thermoplastics possible.

Advantageously, Espancel® microspheres are used as the expandable material in admixture with an ethylene vinyl acetate, especially including high and low viscosity ethylene vinyl acetate. This has proven to be a particularly reliable mixture, which is thermally activated.

Advantageously, the yarn is chosen so that its diameter after coating or sheathing, but before expansion of the expandable material, is in the range of 1 to 2 mm, in particular 1.4 mm. The sheathing is chosen so that advantageously after carried out expansion, a diameter in the range of 4-6 mm, in particular of 5 mm, is achieved. The weight per unit area may in particular be between 200 and 1,000 g / m 2. An inventive method for producing a coated or coated yarn, in particular according to one of claims 7 to 12 includes or has the following steps. First, an expandable material is compounded. This is usually done by mixing at least one foam wall former and at least one foaming agent. Advantageously, the expandable material is melted in extruders and mixed, and in particular subsequently granulated again. Alternatively, an expandable material may be provided. This is followed by overmolding of a yarn core, in particular of plastic with the expandable material. In this case, a coated or coated yarn is produced. The encapsulation does not have to take place over the entire length or over the entire circumference of the yarn. For special applications, an exclusively partial encapsulation of a yarn core is conceivable. Thus, for example, this can be extrusion-coated only in an angular segment, for example half-sided or only in certain sections. For extrusion coating, an extrusion spinning system, in particular with a cross-spray head and / or pressure-coating or coating tool, is advantageously used. Such systems are, in particular from the cable industry, known in the art and can thus be used according to the invention.

By such a method can be produced in a simple manner, an inventive yarn.

The object is also achieved by a knit fabric or woven fabric, in particular in the form of a knitted or knitted fabric, comprising at least one inventive yarn in the expanded and / or unexpanded, but expandable state. Such a knit or woven fabric does not necessarily have to be a textile. Also, the use of other fibers for the production of a knit fabric or fabric is conceivable. It is also largely unessential in which form and / or arrangement at least one inventive yarn is included. Advantageously, however, the yarn has a certain connection to the rest of the mesh and / or woven fabric. Although it is conceivable in principle, the yarn simply hang up or adjacent to arrange in any other way and to create a connection to the mesh or woven fabric by a later, especially during the expansion or after the expansion, compound or fusion. However, it is preferred to connect the yarn according to the invention, in particular by knitting or weaving, with the knit fabric or woven fabric, so that a secure connection is also ensured before or during the expansion.

Depending on the application, the knit fabric or woven fabric fulfills its function both in the expanded and / or unexpanded state. In the expanded state, for example, a finished product, such as an insulating material can be created. In the unexpanded state, it is possible, for example, to create a raw product or also a product for adaptation to a shape and subsequent expansion. It is also conceivable that an expansion takes place during the use of the knit fabric or woven fabric. This can be done for example by the action of heat, in particular in or near fire, or in contact with a medium such as water. Thus, certain protective functions can be realized by such a mesh fabric or woven fabric. Because, in principle, a mesh fabric or woven fabric with non-expanded yarn according to the invention is significantly more permeable to gases, Liquids and temperature radiation as a mesh or woven fabric with expanded yarn.

Advantageously, the at least one yarn is included as a weft, filling and / or inserting thread in the mesh or woven fabric. In particular, it is advantageously included within a conventional spacer knit, fabric or knit fabric. For this purpose, the spacer fabric / fabric / knit or composite or Klimasteppjersey in particular an upper and a lower, but at least two, sides or layers to form a gap between or in which the yarn of the invention is inserted or fixed there , In particular, the yarn according to the invention is inserted there straight and in particular running parallel to one another, in particular unmackled. Advantageously, however, connections between the individual layers, between which the yarn is inserted, are provided. Such are advantageously introduced directly in the production of the mesh or woven fabric. However, they can also be subsequently effected, for example by seams. Advantageously, the compounds are chosen or designed so that after expansion of the at least one yarn through these compounds, a constriction of the woven fabric or knit fabric is effected. This means that the compounds, optionally in cooperation with the respective layers limit the expansion of the yarn at least in one spatial direction.

By such a connection, the cohesion of the mesh fabric and / or woven fabric is guaranteed. As a result, the position of the inserted yarns is secured if they are not even or only little meshed or secured in any other way. Also, such a grid can be created by such compounds, within which also the lateral offset of the yarns can be restricted.

Constrictions of the woven fabric or knit fabric not only lead to a preferred appearance, but also ensure a special compressibility, since they can lead to a bias in the expanded volume and / or mesh or woven fabric.

Advantageously, a plurality of yarns, in particular runs parallel. As a result, the advantages of the yarn according to the invention can be utilized not only locally but over a wide area or over the entire knit fabric or woven fabric.

Advantageously, the expansion of the at least one yarn in the knit or woven fabric according to the invention leads to an increase in the thickness of the knit fabric. In particular, an enlargement of the distance between an upper and a lower layer, but at least between two layers is achieved. In this case, this increase in the distance does not take place over the entire surface. In particular, it may also be constricted by sections between the layers or completely prevented in sections. This is to be preferred, in particular if a tension is exerted on the connections or a pressure that presses the layers apart is caused by this restriction or prevention.

Such a bias in the mesh or woven material leads to a particularly adjustable compressibility, such as in seats, leads to a special comfort. The object is also achieved by a method for producing a woven fabric or knit fabric, in particular one in the form of a knitted or knitted fabric, in which at least one yarn according to one of claims 7 to 12 and / or a yarn produced according to claim 13 is used. In this case, the yarn is at least not fully expanded state. This means that the yarn can at least be further expanded by appropriate influences. It is introduced as a weft, insertion and / or filling thread. In this case, a plurality, in particular parallel, inventive or inventively produced yarns are advantageously used. These are in particular unmasched and introduced in particular as an intermediate layer. Advantageously, an expansion of the at least one yarn is subsequently effected. The expansion takes place in particular after shaping, molding, processing and / or installation of the woven fabric or knit fabric. This makes it possible to achieve a special form faithfulness in a simple way. Advantageously, the expansion is carried out so that a filling of a gap is effected and wherein in particular subsequently the at least one yarn is set by setting the environmental condition in a solid state. Such an expansion produces a particularly advantageous woven fabric or knit fabric in a simple manner.

Advantageously, in the production according to claim 6 at least two woven fabric and / or Maschenstofflagen created, the punctiform and / or linearly arranged compounds (also karoförmig) have each other. In this case, the at least one yarn is arranged between these layers. As a result, a firm connection of the woven fabric and / or knit fabric and the yarn or yarn according to the invention is produced, even if no other compounds are provided. In this case, the connections are in particular dimensioned such that they at least limit the expansion of the at least one yarn in cooperation with the layers, and thus in particular a tension of the connection and / or the layers is effected. In this way, a self-prestressed woven fabric or knit fabric can be obtained in a simple manner.

As a soul, for example, polyester, polyamide, cotton, cellulose, polypropylene, PLA, PVA and in particular with a titre of Nm 5 to Nm 100 or synthetic souls dtex 50 to dtex 400 in question.

The object is also achieved by a method for producing a cover or clothing, boarder for mattresses, mattress covers, hygiene products, water sports products, life jackets, buoyancy aids, insulation material, protective clothing or armchairs or chair, an automotive interior trim and seats of a wall covering having a cover thereby characterized in that the cover or the clothing mesh or woven fabric according to one of claims 1 to 4 and / or yarn according to one of claims 7 to 12 and / or manufactured according to a method according to claims 5, 6, 13 or consists thereof. In this case, the expansion of the yarn is carried out only after sewing, gluing, molding and / or molding of the knit fabric, woven fabric or yarn and the yarn is set after expansion by adjusting the environmental conditions in a solid state, if such does not exist anyway. For the solid state above applies. He does not have to be stiff. In particular, the expansion is performed so that a bias in the mesh or woven fabric is generated.

The object is also achieved by using the knitted or woven fabric according to one of claims 1 to 4 or a yarn according to one of claims 7 to 12 as a fabric for armchairs and chairs, as automotive interior trim, mattress cover, wall covering, boarder for mattresses, hygiene products, water sports products , Life-jackets, swimming aids, insulating material, protective clothing and / or clothing.

In such a use, the advantages of the substance according to the invention come particularly to advantage.

Fig. 1

eine etwas vergrößerte fotografische Draufsicht auf einen Ausschnitt eines erfindungsgemäßen Maschenstoffes in Form eines Gestricks, bei dem die erfindungsgemäß ummantelten nicht aufgeschäumten Garne parallel nebeneinander liegend ein Abstandsgestrick durchlaufen und seitlich herausragen;

Fig. 2

eine fotografische Draufsicht auf den Ausschnitt des in Fig. 1 gezeigten Maschenstoffs in Form eines Gestricks, das in senkrechter Richtung gedehnt worden ist und die horizontal das Abstandsgestrick laufenden ummantelten, nicht aufgeschäumten Garne gut zeigt;

Fig. 3

eine etwas vergrößerte fotografische Draufsicht auf einen Ausschnitt eines erfindungsgemäßen Maschenstoffes in Form eines Gestricks, bei dem die erfindungsgemäß ummantelten Garne aufgeschäumt sind und bei dem die zwei Lagen des Abstandsgestricks durch karoartig angeordnete Verbindungen zusammengehalten werden;

Fig. 4

eine etwas vergrößerte fotografische Perspektivansicht von der Seite des in Fig. 3 gezeigten erfindungsgemäßen Maschenstoffes in Form eines Gestricks; und

Fig. 5

eine schematische, vergrößerte Darstellung in Form eines Querschnitts durch das erfindungsgemäß ummantelte Garn in seinem nicht-expandierten (A) und expandierten (B) Zustand.

Further advantages and features of the invention will become apparent from the claims and in particular from the following description of an embodiment, which is intended to illustrate the invention and not limited in any way. It shows:

Fig. 1

a somewhat enlarged photographic plan view of a section of a knit fabric according to the invention in the form of a knit fabric in which the non-foamed yarns coated according to the invention run parallel through a spacer fabric and protrude laterally;

Fig. 2

a photographic top view of the detail of the in Fig. 1 shown knitted fabric in the form of a knitted fabric which has been stretched in the vertical direction and the horizontally shows the spacer fabric running coated, non-foamed yarns well;

Fig. 3

a somewhat enlarged photographic plan view of a section of a knit fabric according to the invention in the form of a knitted fabric in which the yarns sheathed according to the invention are foamed and in which the two layers of the spacer knit are held together by karoartig arranged connections;

Fig. 4

a slightly enlarged photographic perspective view from the side of the in Fig. 3 shown mesh fabric according to the invention in the form of a knitted fabric; and

Fig. 5

a schematic, enlarged view in the form of a cross section through the invention sheathed yarn in its unexpanded (A) and expanded (B) state.

Fig. 1 shows a photographic plan view of a section of a fabric according to the invention. Evident is a knitted fabric 10 which includes sheathed yarns 12 according to the invention. These are inserted parallel in a gap 20 between an upper layer 16 and a lower layer 18.

Fig. 2 shows an enlarged section Fig. 1 where the knitted fabric 10 in the illustration in Fig. 2 for ease of illustration was stretched slightly in the direction perpendicular to the yarns 12 according to the invention. Evident is the knitted fabric 10 with its individual stitches and the parallel inserted in a gap 20 yarns 12th

Fig. 3 shows a plan view of a fabric 10 with line-shaped and crossing arranged connections 18, which lead to a constriction and form a karoartiges pattern. Shown here is the knitted fabric 10 after an expansion of the yarn 12. Individual fibers or components of the expanded yarn 12 can be seen hanging out from the side.

Fig. 4 shows a cross section through the fabric 10 with expanded yarns Fig. 3 , Evident are the constrictions caused by the connections 18. Evident are also the upper layer 16 and the lower layer 18 and the filled and expanded by the expansion gap 20.

Fig. 5 shows a schematic view of an expanded yarn ( Fig. 5b ) and an unexpanded yarn ( Fig. 5a ). The soul 22 as well as the sheathing or coating 24 can be seen in each case. It is in each case an inventive yarn 12 which has been foamed by the temperature increase (from FIG Fig. 5a to Fig. 5b ).

LIST OF REFERENCE NUMBERS

10

knitted

12

yarn

14.16

upper, lower layer

18

links

20

gap

22

soul

24

Coating or sheathing

Claims (15)

Knitted fabric or woven fabric, in particular in the form of a knitted fabric such as right / left fabric, right / right fabric or left / left fabric, knitted fabric, composite fabric, climate control fabric containing at least one yarn according to any one of claims 7 to 12 in the expanded and / or unexpanded expandable state. A knit or woven fabric according to claim 1, characterized in that the at least one yarn is included as a weft, filling and / or insert yarn, in particular within a conventional spacer knitted fabric, -woven or -gewirks, in particular an upper and a lower side, the lower Forming a gap are spaced from each other, having, in particular in a space, in particular straight and in particular unmasched, is inserted and in particular connections, between two layers of the spacer knitted fabric or -gewirks, in particular, the upper and the lower side is provided which leads after expansion of the at least one yarn according to one of claims 7 to 1 2 to a constriction of the woven fabric or knit fabric. Mesh or woven fabric according to one of the preceding claims, wherein a plurality of yarns according to any one of claims 7 to 12, in particular running parallel, including. A knit or woven fabric according to any one of the preceding claims 1 to 3, wherein the expansion of the at least one yarn leads to or has led to an increase in the thickness of the knit fabric, in particular an increase in the distance of an upper and a lower layer and, in particular, constrictions are present Have locally limited or limited expansion and / or increase in thickness, and in particular by the expansion of a pressure between two layers of the mesh or woven fabric, particularly an upper and a lower layer, is effected or has been. A process for producing a woven fabric or knit fabric, in particular in the form of a knitted or knitted fabric, wherein at least one, in particular a plurality, in particular parallel, yarn according to one of claims 7 to 12 and / or produced according to claim 13, in at least not fully expanded State as a weft, insertion and / or filling thread, in particular unmasched, in particular as an intermediate layer is introduced, and in particular subsequently, in particular after shaping, molding, processing and / or installation of the woven fabric or knit fabric, an expansion of the at least one yarn, in particular by In particular, the expansion is carried out so that a filling of a gap is effected and in particular then the at least one yarn is set by setting the environmental conditions in a solid state. Method according to claim 5, wherein two woven fabric and / or mesh layers are provided which have punctiform and / or linearly arranged connections, and wherein the at least one yarn is arranged between the layers, and in particular the connections are dimensioned so that they interact with the layers limit the expansion of the at least one yarn and thus in particular a tension of the compounds and / or the layers is effected. Yarn comprising a core, in particular of plastic, and a coating or sheath of expandable, in particular foamable, material which, due to temporarily adjustable external conditions, in particular setting a minimum temperature, causes an increase in the overall diameter of the yarn, in particular the yarn after the increase diameter, in particular after restoring the original external conditions and / or producing the Operating conditions for the yarn, especially after lowering the temperature below the minimum temperature, is a solid. Yarn according to claim 7, wherein the expandable material comprises at least one foaming agent, in particular containing hydrocarbon, and at least one Schaumwandbildner, in particular at least one polymer material, in particular thermoplastic material, wherein the foaming agent is in particular encapsulated, in particular, in particular thermoplastic, hollow spheres is included. Yarn according to any one of the preceding claims 7 to 8, characterized in that the polymeric material is thermoplastic and comprises one or more elevated-temperature foamable microspheres formed by small hollow thermoplastic spheres, the envelopes of which contain hydrocarbon droplets which evaporate at elevated temperature and expansion cause the microspheres in self-curing. Yarn according to one of the preceding claims 8 or 9, characterized in that the hydrocarbon droplets evaporate at elevated temperature in the range of 140-230 ° C, especially 175 ° C. Yarn according to one of the preceding claims 7 to 10, characterized in that microspheres of Espancel, in particular 930MB120, are included in admixture with an ethylene vinyl acetate (EVA), in particular Espancel 930MB120 mixed with high and low viscosity ethylene vinyl acetate mixed as expandable material. Yarn according to one of the preceding claims 7 to 11, characterized in that its diameter after coating or sheathing and before expansion in the range of 1-2 mm, in particular 1.4 mm, and after carried out expansion in the range of 4-6 mm , in particular 5 mm, is located. Process for producing a coated or coated yarn, in particular according to one or more of the preceding claims 7 to 12, characterized by the following steps: a. Compounding the expandable material, in particular in the form of granules or providing the expandable material, b. at least partially encapsulating a yarn core, in particular made of plastic, with the expandable material, in particular using an extrusion spinning system, in particular with a crosshead and / or tool for pressure coating or coating a yarn core, in particular of plastic, with the expandable material to produce a coated or covered yarn. A method of manufacturing a cover, mattress rug, mattress covers, hygiene products, water sports products, lifejackets, buoyancy aids, insulating material, protective clothing or clothing or armchairs, chairs, automotive interior trim and seat fabrics, a wall covering having a cover, characterized in that the cover or the A garment, product or material, knitted or woven fabric according to any one of claims 1 to 4 and / or yarn according to any one of claims 7 to 12 or made according to any of claims 5, 6 or 13, or consisting thereof and wherein the expanding of the yarn only after sewing, gluing, molding and / or shaping of the mesh, woven fabric or yarn takes place and the yarn is then set by adjusting the environmental conditions in a solid state. Use of the knitted or woven fabric according to any one of claims 1 to 4 and / or a yarn according to any one of claims 7 to 12 as a fabric for armchairs and chairs, automotive interior trim and seat fabrics, mattress covers, wall coverings, mattress boards, hygiene products, water sports products , Life-jackets, swimming aids, insulating material, protective clothing and / or clothing.

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