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US20170101729A1 - Method of manufacturing stab-resistant fabric using water punching - Google Patents

Method of manufacturing stab-resistant fabric using water punching Download PDF

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Publication number
US20170101729A1
US20170101729A1 US15/032,804 US201515032804A US2017101729A1 US 20170101729 A1 US20170101729 A1 US 20170101729A1 US 201515032804 A US201515032804 A US 201515032804A US 2017101729 A1 US2017101729 A1 US 2017101729A1
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United States
Prior art keywords
fabric
stab
aramid
water punching
water
Prior art date
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Abandoned
Application number
US15/032,804
Inventor
Young Kyu RHEE
Kyung Ju Lee
Chang Hwan Lee
Hu Fan HONG
Nan Sae LEE
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WELCRON CO Ltd
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WELCRON CO Ltd
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Assigned to WELCRON CO., LTD. reassignment WELCRON CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HONG, Hu Fan, LEE, CHANG HWAN, LEE, KYUNG JU, LEE, NAN SAE, RHEE, YOUNG KYU
Publication of US20170101729A1 publication Critical patent/US20170101729A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D04H1/4342—Aromatic polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H1/00—Personal protection gear
    • F41H1/02—Armoured or projectile- or missile-resistant garments; Composite protection fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • F41H5/0485—Layered armour containing fibre- or fabric-reinforced layers all the layers being only fibre- or fabric-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B32B2307/581—Resistant to cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment

Definitions

  • the present invention relates to stab-resistant fabric, and more particularly, to a method of manufacturing stab-resistant fabric using water punching.
  • stab-resistant vest including stab-proof clothing, stab-proof gloves, or the like
  • stab-resistant fabric for effectively protecting bodies or the like from impact of a sharp object such as a knife or awl
  • existing stab-resistant vest stab-resistant fabric
  • stab-resistant fabric is heavy in weight and stiff in texture, which are not desirable for activities.
  • a stab-resistant vest is manufactured, a multilayer stab-resistant material is stacked such that a knife or an awl cannot penetrate therethrough, and a thin metal plate or high-strength plastic and fabric coated with inorganic particles, and the like are used.
  • a stab-resistant vest is inevitably heavy and stiff, causing a wearer to slow in movement.
  • Korean Patent No. 1385003 (entitled Stab-resistant fabric with inorganic particles attached thereto and manufacturing method thereof) of the present applicant proposes a method of increasing flexibility of fabric by attaching inorganic particles such as alumina, titanium dioxide, or silicon carbide to aramid fiber formed of yarn with high tenacity or treating a manufactured stab-resistance fabric with a softening agent.
  • the stab-resistant fabric manufactured by the above method is reduced in weight and has increased flexibility, compared with an existing stab-resistant fabric, but disadvantageously has a short endurance term in that the inorganic particles attached to the surface of the fabric may be separated.
  • the present invention has been made in view of the above problems of the prior arts, and it is a primary object of the present invention to provide stab-resistant fabric which is light in overall weight compared with an existing stab-resistant vest by enhancing stab-resistance performance of fabric itself.
  • Another object of the present invention is to provide stab-resistant fabric supporting excellent activity through lightness.
  • a method of manufacturing stab-resistant fabric using water punching including: interlacing an aramid nonwoven fabric in a high strength fabric formed of aramid yarn through water punching.
  • the present inventors recognized that the stab-resistance performance can be increased by enhancing the density of stab-resistant fabric by interlacing a micro-aramid fiber (aggregate) constituting an aramid nonwoven fabric in a high strength fabric formed of aramid yarn through a water punching process using high pressure water, and devised the present invention.
  • High strength fabric as biaxial fiber aggregate is formed using high strength aramid nonwoven fabric or filament yarn as uniaxial fiber aggregate.
  • Fiber is preferably fabric, and twilled fabric or plain fabric is illustrated.
  • the density of fiber should be high, and knitted work has relatively low density compared with fabric, and thus, plain fabric or twilled fabric is selected.
  • the aramid yarn is preferably spun yarn 40/3 (tex 40/strands 3) to 60/2 or 500 to 600 denier filament yarn, and this is for appropriate fabric density and integration of yarn in fabric.
  • the density of the fiber is 30 ⁇ 30 ply (wrap threads ⁇ weft threads) to 85 ⁇ 85 ply (wrap threads ⁇ weft threads)/5 cm
  • a basic weight is 100 to 200 gsm
  • air permeability is 5 cm 3 /cm 2 /s or greater.
  • the density is less than 30 ⁇ 30 ply/5cm, stab-resistance performance is weak, and when the density exceeds 85 ⁇ 85 ply/cm, there is a difficulty in weaving fabric. It is preferable to have 60/2, 85 ⁇ 75 ply/5 cm, and 140 gsm.
  • the air permeability of the fabric is less than 5 cm 3 /cm 2 /s, a suction function within a roller is impossible to perform, making interlacing between aramid fabric and nonwoven fabric defective or making it impossible to interlace aramid fiber and nonwoven fabric.
  • the nonwoven fabric formed of aramid fiber having fineness of 3 to 6 denier, and having a basic weight of 40 to 70 gsm and air permeability of 100 cm 3 /cm 2 /s or greater is illustrated. The range of the above numerical values is selected in consideration of penetration of nonwoven fiber into aramid fiber.
  • the present invention features that, in a state where aramid nonwoven fabric is positioned on aramid fabric, a high pressure fluid is jetted from the nonwoven fabric toward the aramid fabric to allow the nonwoven fabric to be interlaced to be combined between the fiber of the aramid fabric.
  • a high pressure fluid is jetted from the nonwoven fabric toward the aramid fabric to allow the nonwoven fabric to be interlaced to be combined between the fiber of the aramid fabric.
  • the combining of the aramid fabric and the nonwoven fabric is performed through water punching without using a separate adhesive, and the aramid fabric and the nonwoven fabric are combined to form integrated fabric.
  • Water punching is a method of allowing fiber to continuously pass with high pressure water to increase the density of fiber and a combining force between fibers, and as the strength (water pressure) of water punching is increased, the rigidity of aramid fabric is increased and the interlacing between nonwoven fabric and fiber is increased.
  • the water pressure of water punching may be 50 to 250 bar.
  • a water punching pattern may appear on a surface of the fabric. Such stripe pattern may be removed through random vibration. If the pressure is less than 50 bar, inter-fiber combining is not normally made to degrade strength and the fibers may be easily separated, and if the pressure is greater than 250 bar, good performance may be obtained but elongation is lowered to reduce flexibility.
  • the fabric may be water-punched with low water pressure to restrain damage to the fabric, and the fabric may be water-punched with high water pressure during a main water punching process to allow the fibers to be effectively interlaced and allow a portion of aramid nonwoven fabric to push into the surface of the aramid fabric so as to be combined in a wedge form, thus manufacturing stab-resistant fabric having strong combining force.
  • water punching may move the fabric at a speed of 3 m/min or higher, preferably, at a speed of 3 to 10 m/min. If the moving speed of the fabric is too high, interlacing may be defective, and if the moving speed thereof is too low, mass-production of the fabric manufacturing process is degraded.
  • the composite aramid fabric manufactured in the present invention When the composite aramid fabric manufactured in the present invention is not properly dried, stab-resistance performance may be degraded, and thus, it is preferred that the fabric undergoes a dry process at a temperature of about 240° C. for 60 seconds after the water punching process.
  • FIG. 1 is a surface-enlarged photograph of general aramid fabric.
  • FIG. 2 is a surface-enlarged photograph of general aramid nonwoven fabric.
  • FIG. 3 is a conceptual view of a water punching apparatus for manufacturing composite aramid fabric according to an embodiment of the present invention
  • Aramid fabric (plain fabric) having 60/2, 85 ⁇ 75 ply/5 cm and basic weight of 140 gsm using Kevlar of DuPont as yarn and Heracron nonwoven fabric (40 gsm) of Kolon as reinforced fabric were prepared.
  • preliminary interlacing was performed with pressure of 70 bar by nozzle #1 of a water punching device.
  • Secondary interlacing was performed respectively with pressure of 100 bar by nozzle #2 and with pressure of 110 bar by nozzle #3 through a subsequent continuous process.
  • Main interlacing was performed with pressure of 250 bar by nozzle #4.
  • stripe patterns formed at predetermined intervals were removed with pressure of 100 bar and through random vibration by nozzle #5.
  • the interlaced aramid fabric was dried at a dry temperature of 240° C. for 60 seconds and wound to obtain stab-resistant fabric having a basic weight of 180 g/m 2 .
  • Aramid fabric (plain fabric) having 60/2, 85 ⁇ 75 ply/5 cm and a basic weight of 140 gsm using Kevlar of DuPont as yarn was prepared.
  • Embodiment 1 shows that the stab-resistance performance of the composite aramid fabric using water punching according to the present invention is superior, although it is light in weight, compared with otherwise fabric.
  • stab-resistant fabric capable of effectively protecting it from impact of a sharp object such as a knife or awl is provided. Further, the present invention can also be used in manufacturing a stab-resistant vest or the like supporting excellent activity through lightness.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)
  • Woven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

A method of manufacturing stab-resistant fabric using water punching is provided. Aramid fabric and nonwoven aramid fabric are combined through water punching, thereby enhancing activities by ensuring flexibility and stab-resistance performance, and the method is an aramid composite fabric manufacturing method which performs water punching with pressure of 50 to 250 bar when the water punching is performed.

Description

    FIELD OF THE INVENTION
  • The present invention relates to stab-resistant fabric, and more particularly, to a method of manufacturing stab-resistant fabric using water punching.
    • BACKGROUND OF THE INVENTION
  • In developing a stab-resistant vest (including stab-proof clothing, stab-proof gloves, or the like) or stab-resistant fabric for effectively protecting bodies or the like from impact of a sharp object such as a knife or awl, existing stab-resistant vest (stab-resistant fabric) is heavy in weight and stiff in texture, which are not desirable for activities.
  • This is because when a stab-resistant vest is manufactured, a multilayer stab-resistant material is stacked such that a knife or an awl cannot penetrate therethrough, and a thin metal plate or high-strength plastic and fabric coated with inorganic particles, and the like are used. Such a stab-resistant vest is inevitably heavy and stiff, causing a wearer to slow in movement.
  • Thus, as a method for improving such a stab-resistant vest (or stab-resistant clothing), a demand for developing stab-resistant fabric, having the greatest importance in stab-resistant vest, to develop a product which is light in overall weight and supports excellent activity has grown.
  • In order to manufacture a stab-resistant vest supporting excellent activity, Korean Patent No. 1385003 (entitled Stab-resistant fabric with inorganic particles attached thereto and manufacturing method thereof) of the present applicant proposes a method of increasing flexibility of fabric by attaching inorganic particles such as alumina, titanium dioxide, or silicon carbide to aramid fiber formed of yarn with high tenacity or treating a manufactured stab-resistance fabric with a softening agent.
  • The stab-resistant fabric manufactured by the above method is reduced in weight and has increased flexibility, compared with an existing stab-resistant fabric, but disadvantageously has a short endurance term in that the inorganic particles attached to the surface of the fabric may be separated.
  • Thus, it is required to develop fabric itself having excellent stab-resistance performance.
    • SUMMARY OF THE INVENTION
  • Therefore, the present invention has been made in view of the above problems of the prior arts, and it is a primary object of the present invention to provide stab-resistant fabric which is light in overall weight compared with an existing stab-resistant vest by enhancing stab-resistance performance of fabric itself.
  • Another object of the present invention is to provide stab-resistant fabric supporting excellent activity through lightness.
  • According to one aspect of the present invention, there is provided a method of manufacturing stab-resistant fabric using water punching, including: interlacing an aramid nonwoven fabric in a high strength fabric formed of aramid yarn through water punching.
  • The present inventors recognized that the stab-resistance performance can be increased by enhancing the density of stab-resistant fabric by interlacing a micro-aramid fiber (aggregate) constituting an aramid nonwoven fabric in a high strength fabric formed of aramid yarn through a water punching process using high pressure water, and devised the present invention.
  • High Strength Aramid Fabric
  • High strength fabric as biaxial fiber aggregate is formed using high strength aramid nonwoven fabric or filament yarn as uniaxial fiber aggregate. Fiber is preferably fabric, and twilled fabric or plain fabric is illustrated. In order to achieve a stab-resistance function, the density of fiber should be high, and knitted work has relatively low density compared with fabric, and thus, plain fabric or twilled fabric is selected.
  • Further, in the present invention, the aramid yarn is preferably spun yarn 40/3 (tex 40/strands 3) to 60/2 or 500 to 600 denier filament yarn, and this is for appropriate fabric density and integration of yarn in fabric.
  • Also, in the present invention, the density of the fiber is 30×30 ply (wrap threads×weft threads) to 85×85 ply (wrap threads×weft threads)/5 cm, a basic weight is 100 to 200 gsm, and air permeability is 5 cm3/cm2/s or greater. When the density is less than 30×30 ply/5cm, stab-resistance performance is weak, and when the density exceeds 85×85 ply/cm, there is a difficulty in weaving fabric. It is preferable to have 60/2, 85×75 ply/5 cm, and 140 gsm. Also, if the air permeability of the fabric is less than 5 cm3/cm2/s, a suction function within a roller is impossible to perform, making interlacing between aramid fabric and nonwoven fabric defective or making it impossible to interlace aramid fiber and nonwoven fabric.
  • Aramid Nonwoven Fabric
  • Nonwoven fabric manufactured by entwisting aramid web using spunlace through a non-adhesive water jet stream or collecting aramid web in a conveyer belt and then needle-punching it is appropriate. The nonwoven fabric formed of aramid fiber having fineness of 3 to 6 denier, and having a basic weight of 40 to 70 gsm and air permeability of 100 cm3/cm2/s or greater is illustrated. The range of the above numerical values is selected in consideration of penetration of nonwoven fiber into aramid fiber.
  • Water Punching Process
  • The present invention features that, in a state where aramid nonwoven fabric is positioned on aramid fabric, a high pressure fluid is jetted from the nonwoven fabric toward the aramid fabric to allow the nonwoven fabric to be interlaced to be combined between the fiber of the aramid fabric. Here, the combining of the aramid fabric and the nonwoven fabric is performed through water punching without using a separate adhesive, and the aramid fabric and the nonwoven fabric are combined to form integrated fabric.
  • Water punching is a method of allowing fiber to continuously pass with high pressure water to increase the density of fiber and a combining force between fibers, and as the strength (water pressure) of water punching is increased, the rigidity of aramid fabric is increased and the interlacing between nonwoven fabric and fiber is increased.
  • In the present invention, the water pressure of water punching may be 50 to 250 bar. When water punching is continuously performed with water pressure of 50 to 250 bar, a water punching pattern may appear on a surface of the fabric. Such stripe pattern may be removed through random vibration. If the pressure is less than 50 bar, inter-fiber combining is not normally made to degrade strength and the fibers may be easily separated, and if the pressure is greater than 250 bar, good performance may be obtained but elongation is lowered to reduce flexibility. At an initial stage, the fabric may be water-punched with low water pressure to restrain damage to the fabric, and the fabric may be water-punched with high water pressure during a main water punching process to allow the fibers to be effectively interlaced and allow a portion of aramid nonwoven fabric to push into the surface of the aramid fabric so as to be combined in a wedge form, thus manufacturing stab-resistant fabric having strong combining force.
  • In case of a multistage water punching process greater than one stage, how strong water pressure is to be applied by stages may be determined by a person skilled in the art as necessary.
  • In the present invention, water punching may move the fabric at a speed of 3 m/min or higher, preferably, at a speed of 3 to 10 m/min. If the moving speed of the fabric is too high, interlacing may be defective, and if the moving speed thereof is too low, mass-production of the fabric manufacturing process is degraded.
  • When the composite aramid fabric manufactured in the present invention is not properly dried, stab-resistance performance may be degraded, and thus, it is preferred that the fabric undergoes a dry process at a temperature of about 240° C. for 60 seconds after the water punching process.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • The above and other objects and features of the present invention will become apparent from the following description of embodiments, given in conjunction with the accompanying drawings, in which:
  • FIG. 1 is a surface-enlarged photograph of general aramid fabric.
  • FIG. 2 is a surface-enlarged photograph of general aramid nonwoven fabric.
  • FIG. 3 is a conceptual view of a water punching apparatus for manufacturing composite aramid fabric according to an embodiment of the present invention;
    •  DETAILED DESCRIPTION OF THE EMBODIMENT
  • Hereinafter, an embodiment of the present invention will be described.
    • Embodiment 1
  • Aramid fabric (plain fabric) having 60/2, 85×75 ply/5 cm and basic weight of 140 gsm using Kevlar of DuPont as yarn and Heracron nonwoven fabric (40 gsm) of Kolon as reinforced fabric were prepared. In FIG. 3, preliminary interlacing was performed with pressure of 70 bar by nozzle #1 of a water punching device. Secondary interlacing was performed respectively with pressure of 100 bar by nozzle #2 and with pressure of 110 bar by nozzle #3 through a subsequent continuous process. Main interlacing was performed with pressure of 250 bar by nozzle #4.
  • In addition, stripe patterns formed at predetermined intervals were removed with pressure of 100 bar and through random vibration by nozzle #5. The interlaced aramid fabric was dried at a dry temperature of 240° C. for 60 seconds and wound to obtain stab-resistant fabric having a basic weight of 180 g/m2.
    • Comparative Example 1
  • Aramid fabric (plain fabric) having 60/2, 85×75 ply/5 cm and a basic weight of 140 gsm using Kevlar of DuPont as yarn was prepared.
  • Stab-resistance performances of the fabric of Embodiment 1 of the present invention and the fabric of Comparative Example 1 prepared above were tested based on NIJ Standard 0115.00 (E1).
  • TABLE 1
    Total Basic Stab-resistance
    weight (g/m2) weight (g/m2) performance (mm)
    Embodiment 1 3600 180 2
    Comparative 3780 140 5
    Example 1
  • The comparison between Embodiment 1 and Comparative Example 1 shows that the stab-resistance performance of the composite aramid fabric using water punching according to the present invention is superior, although it is light in weight, compared with otherwise fabric.
  • According to the present invention described above, stab-resistant fabric capable of effectively protecting it from impact of a sharp object such as a knife or awl is provided. Further, the present invention can also be used in manufacturing a stab-resistant vest or the like supporting excellent activity through lightness.
  • While the invention has been shown and described with respect to the embodiments, the present invention is not limited thereto. It will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.

Claims (12)

What is claimed is:
1. A method of manufacturing stab-resistant fabric using water punching, comprising:
interlacing an aramid nonwoven fabric in a high strength fabric formed of aramid yarn through water punching.
2. The method of claim 1, wherein a tissue of the high strength fabric is a tissue selected from plain fabric and twilled fabric.
3. The method of claim 1, wherein the aramid yarn is spun yarn 40/3 (tex 40/strands 3) to 60/2 or 500 to 600 denier filament yarn.
4. The method of claim 1, wherein the density of the fabric is 30×30 ply (wrap threads×weft threads) to 85×85 ply (wrap threads×weft threads)/5 cm, a basic weight is 100 to 200 gsm, and air permeability is 5 cm3/cm2/s or greater.
5. The method of any one of claim 1, wherein the nonwoven fabric is formed of aramid fiber having fineness of 3 to 6 denier, and has a basic weight of 40 to 70 gsm and air permeability of 100 cm3/cm2/s or greater.
6. The method of any one of claim 2, wherein the nonwoven fabric is formed of aramid fiber having fineness of 3 to 6 denier, and has a basic weight of 40 to 70 gsm and air permeability of 100 cm3/cm2/s or greater.
7. The method of any one of claim 3, wherein the nonwoven fabric is formed of aramid fiber having fineness of 3 to 6 denier, and has a basic weight of 40 to 70 gsm and air permeability of 100 cm3/cm2/s or greater.
8. The method of any one of claim 4, wherein the nonwoven fabric is formed of aramid fiber having fineness of 3 to 6 denier, and has a basic weight of 40 to 70 gsm and air permeability of 100 cm3/cm2/s or greater.
9. The method of any one of claim 1, wherein the water punching is performed with water pressure of 50 to 250 bar.
10. The method of any one of claim 2, wherein the water punching is performed with water pressure of 50 to 250 bar.
11. The method of any one of claim 3, wherein the water punching is performed with water pressure of 50 to 250 bar.
12. The method of any one of claim 4, wherein the water punching is performed with water pressure of 50 to 250 bar.
US15/032,804 2015-04-02 2015-10-27 Method of manufacturing stab-resistant fabric using water punching Abandoned US20170101729A1 (en)

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JP2017527702A (en) 2017-09-21
JP6289671B2 (en) 2018-03-07
KR101542736B1 (en) 2015-08-10

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