Patent Publication Number: US-2019191801-A1

Title: Gauze fabric

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. application Ser. No. 14/767,775 filed Aug. 13, 2015, the entire contents of which is incorporated herein by reference. U.S. application Ser. No. 14/767,775 is a 371 of International Application No. PCT/JP2013/073157 filed Aug. 29, 2013. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a gauze fabric. 
     BACKGROUND ART 
     Gauze fabrics are a coarse-meshed plain woven fabric. For example, a cotton yarn (a single yarn of a yarn count of 40) is used for weaving the gauze fabrics. Exemplary patterns of the gauze fabrics include a single woven fabric, a double woven fabric, and a triple woven fabric. The single gauze fabric is employed, for example, for medical use and as a dishcloth. The double gauze fabric is employed for clothing, handkerchief, etc. The triple gauze fabric is employed for towels, bed and bedding, etc. 
     Unless otherwise mentioned, in common knowledge of one skilled in the art, gauze is made of only cotton yarn. 
     Unless otherwise mentioned, in common knowledge of those skilled in the art, a cotton yarn is made entirely of cotton fiber. One skilled in the art would not call composite yarn as “cotton yarn.” 
     Unless otherwise mentioned, in common knowledge of one skilled in the art, a cotton yarn is formed by twisting raw cotton fibers. So spun yarn means a twisted yarn generally. 
       FIG. 5  shows the twisted yarn as the common general technical knowledge of one skilled in the art. The twisted yarn of  FIG. 5  is made entirely of cotton fiber. 
     To the contrary, a non-twisted yarn is formed by untwisting a twisted yarn to return it to a non-twisted state. How to form “non-twisted yarn” is explained below. PVA is wound the cotton twisted yarn, opposite direction to the cotton yarn twist direction. The twist of the cotton yarn is canceled by the opposite twist of PVA. The cotton yarn becomes untwisted. When PVA is dissolved, non-twisted yarn remains fluffy and soft. Non-twisted yarn is distinguished with twisted yarn. So one skilled in the art always mention “non”. Someone may mention twistless yarn or zero twist yarn. 
       FIG. 6  shows the non-twisted yarn as the common general technical knowledge of one skilled in the art. The non-twisted yarn of  FIG. 6  is made entirely of cotton fiber. 
     For matters not specifically mentioned, the present invention is interpreted based on the common general knowledge of one skilled in the art. 
     Genellay gauze fabrics have flat appearance except the patent literature 5.  FIG. 7  is an explanatory view to explain the principle of the prior art.  FIG. 8  is an additional explanatory view to explain the principle of the prior art. 
     The triple woven fabric in the prior art has textured polyester filament yarns  14 , 15  as the indispensable element. The textured polyester filament yarns  14 , 15  of middle layer are shrink more than the surface layer and the back layer to form a concave and convex structure in the surface layer and the back layer. The appearance of the triple woven fabric becomes quilt-like. 
     The invention of Patent Document 5 provides the best mode (proper wrinkles for actual use). Something changes make the effect lost. 
     Suppose that the textured polyester filament yarns  14 , 15  are removed. There is no shrink difference between layers and the wrinkle does not occur. The appearance of the triple woven fabric becomes flat. 
     So the textured polyester filament yarns  14 , 15  (chemical yarns) are the indispensable elements for the prior art. 
     CITATION LIST 
     Patent Literature 
     
         
         [Patent Literature 1] 
       
    
     Japanese Unexamined Patent Application, First Publication No. Hei 11-323693
     [Patent Literature 2]   

     Japanese Unexamined Patent Application, First Publication No. 2004-107823
     [Patent Literature 3]   

     Japanese Unexamined Patent Application, First Publication No. 2004-107824
     [Patent Literature 4]   

     Japanese Unexamined Patent Application, First Publication No. 2007-303008
     [Patent Literature 5]   

     Japanese Unexamined Patent Application, First Publication No. 2010-077542 
     SUMMARY OF INVENTION 
     Technical Problem 
     Gauze is a coarse-meshed fabric, i.e., a loosely woven fabric. In comparison with tightly woven fabrics, gauze has a good touch feeling. Because gauze is a coarse-meshed plain woven fabric, even when the gauze is woven into a multiple woven fabric, the resulting fabric will be still thin. Therefore, gauze is poor in bounce and softness. Because of its coarse-meshed structure, gauze is poor in heat-retaining property. Further, because gauze is a coarse-meshed plain fabric, there is a difficulty in sewing. 
     The present invention is made to solve the above problem. Namely, a purpose of the present invention is to provide a gauze fabric having a good touch feeling (a soft touch feeling) and breathability, further being excellent in heat-retaining property, and capable of being sewn. 
     Solution to Problem 
     According to a first aspect of the present invention, proposed is a gauze fabric including 
     a surface layer, 
     a back layer, and 
     at least one middle layer provided between the surface layer and the back layer, 
     wherein the surface layer is composed of non-twisted yarns, 
     wherein the back layer is composed of non-twisted yarns, 
     wherein the at least one middle layer is composed of twisted yarns, and 
     wherein the surface layer and the back layer are directly and/or indirectly joined with each other. 
     According to a second aspect of the present invention, proposed is the gauze fabric, wherein the surface layer and the back layer are joined together via the twisted yarns of the middle layer. 
     According to a third aspect of the present invention, proposed is the gauze fabric, wherein the twisted yarn is made by twisting two or more yarns. 
     According to a fourth aspect of the present invention, proposed is the gauze fabric, wherein the twisted yarn is a double yarn. 
     According to a fifth aspect of the present invention, proposed is the gauze fabric, wherein the non-twisted yarn is selected from yarn count of 30 to yarn count of 80, and yarns composing the twisted yarn are selected from yarn count of 60 to yarn count of 160. 
     According to a sixth aspect of the present invention, proposed is the gauze fabric, wherein the gauze fabric is an N (N is an integer equal to or greater than 3) woven fabric. 
     According to a seventh aspect of the present invention, proposed is the gauze fabric, wherein the gauze fabric is a triple woven fabric. 
     According to an eighth aspect of the present invention, proposed is the gauze fabric, wherein the gauze fabric is a gauze fabric for garment. 
     According to a ninth aspect of the present invention, proposed is clothes manufactured with the gauze fabric. 
     According to a tenth aspect of the present invention, proposed is bedding manufactured with the gauze fabric. 
     Advantageous Effect of Invention 
     The surface layer and the back layer are composed of non-twisted yarns, so that the gauze fabric of the present invention has a soft touch feeling. 
     A gauze fabric composed of only non-twisted yarns is poor in fabric strength. However, the middle layer is composed of twisted yarns here. Therefore, the resulting gauze fabric is rich in fabric strength. With the rich fabric strength, the gauze fabric can be used as a material to be used in various ways. Because of the rich fabric strength, the gauze fabric of the present invention can be sewn. More specifically, the gauze fabric of the present invention can be used as a material for sewn products. 
     Further, a shrinkage rate of the surface layer (back layer) differs from a shrinkage rate of the middle layer. As a result, the gauze fabric comes to have rich three-dimensional appearance (bulkiness). Even with the bulkiness, the gauze fabric is still light in weight. Further, such gauze fabric is excellent in heat-retaining property. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a cross-sectional view of a gauze fabric according to an embodiment of the present invention. 
         FIG. 2  is a cross-sectional view of a gauze fabric according to another embodiment of the present invention. 
         FIG. 3  is an explanatory view compensate for the principle of the present invention. 
         FIG. 4  shows one of actual product appearance of the present invention. 
         FIG. 5  shows the twisted yarn as the common general technical knowledge of one skilled in the art. 
         FIG. 6  shows the non-twisted yarn as the common general technical knowledge of one skilled in the art. 
         FIG. 7  is an explanatory view to explain the principle of the prior art. 
         FIG. 8  is an additional explanatory view to explain the principle of the prior art. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     An embodiment of the present invention will be described below. A first invention is directed to a gauze fabric. The gauze fabric is used in various fields. Specifically, when the gauze fabric is used in a field of garment, the gauze fabric produces a large effect. For example, the gauze fabric is used as a material for clothes (e.g., gown, pajamas, and undershirt). As a matter of course, the use of gauze fabric is not limited to garments. For example, the gauze fabric is employed as a material for the use of various products for infants. For example, the gauze fabric is employed for the use of a material for bedding. The gauze fabric is an N (N is an integer equal to or greater than 3) woven fabric. In the light of weight and cost, N is, preferably, 3, 4, or 5. More preferably, N is 3 (i.e., triple woven fabric). The surface layer of the gauze fabric is composed of non-twisted yarns. The back layer of the gauze fabric is composed of non-twisted yarns. A layer of gauze (at least one layer of gauze) provided between the surface layer and the back layer is composed of twisted yarns. The surface layer and the back layer are directly and/or indirectly joined with each other. For example, the surface layer and the back layer are directly joined together via yarns. Alternatively, the surface layer and the middle layer are directly joined together via yarns (specifically, via twisted yarns composing the middle layer), and the back layer and the middle layer are directly joined together via yarns (specifically, via twisted yarns composing the middle layer). As a result, the surface layer and the back layer are indirectly joined together via the middle layer. The twisted yarn is preferably a yarn which is made by twisting two or more yarns. Most preferable twisted yarn is a double yarn. Preferably, the non-twisted yarn is selected from yarn count of 30 to yarn count of 80 (more preferably, from yarn count of 40 to yarn count of 70). Preferably, a single yarn composing the twisted yarn is selected from yarn count of 60 to yarn count of 160 (more preferably, from yarn count of 80 to yarn count of 140). In a case where the twisted yarn is a double yarn, the twisted yarn is made of a combination of yarns selected from yarn count of 60 to yarn count of 160 (more preferably, from yarn count of 80 to yarn count of 140) and from yarn count of 60 to yarn count of 160 (more preferably, from yarn count of 80 to yarn count of 140). 
     The gauze fabric of the present embodiment has a soft touch feeling. More specifically, the surface layer and the back layer were composed of non-twisted yarns, and thus the resulting gauze fabric comes to have a soft touch feeling. The gauze fabric composed of only the non-twisted yarns is poor in fabric strength. However, the gauze fabric of the present embodiment includes the middle layer which is composed of twisted yarns and thus is rich in fabric strength. Therefore, the resulting gauze is hardly torn even when a load is applied to the gauze. This enables sewing of the gauze. Further, the surface layer (back layer) was composed of non-twisted yarns, and the middle layer was composed of twisted yarns. Therefore, the resulting gauze is rich in three-dimensional appearance. This is because a shrinkage rate of the surface layer (back layer) differs from a shrinkage rate of the middle layer. Unevenness (three-dimensional appearance) caused by the difference of the shrinkage rate and puffiness of yarns resulting from unravelling of yarns increases a thickness of the material. As a result, the material comes to be soft and excellent in heat-retaining property. Further, the material is light in weight for its thickness. 
       FIG. 3  is an explanatory view compensate for the principle of the present invention. The middle layer is twisted yarns that shrink more than the surface layer and the back layer to form a concave and convex structure (three-dimensional appearance) in the surface layer and the back layer. 
     A second invention is directed to clothes (gown, pajamas, undershirt, etc.) or bedding (sheet, blanket, etc.). These products are manufactured with the above described gauze fabric. 
     More specific embodiment will be described below. However, the present invention is not limited to only the following embodiment. Various modifications and applications are also encompassed within the scope of the present invention in so far as features of the present invention are not largely deteriorated. 
       FIG. 1  is a cross sectional view of a gauze fabric (triple gauze fabric) according to a first embodiment of the present invention. 
       1  and  2  denote warps (warp yarns) composing a layer of gauze G 1  that is a first layer (surface layer/upper layer). A and B denote wefts (woof) composing the layer of gauze G 1  that is the first layer. The warps  1  and  2  and the wefts A and B all are non-twisted yarns (single yarns) of a yarn count of 60. 
       3  and  4  denote warps composing a layer of gauze G 2  that is a second layer (middle layer). C and D are wefts composing the layer of gauze G 2  that is the second layer. The warps  3  and  4  and the wefts C and D all are double yarns. The double yarn is a twisted yarn (composed of two yarns of a yarn count of 120). 
       5  and  6  denote warps composing a layer of gauze G 3  that is a third layer (back layer/lower layer). E and F denote wefts composing the layer of gauze G 3  that is the third layer. The warps  5  and  6  and the wefts E and F all are non-twisted yarns (single yarns) of a yarn count of 60. 
     In a gauze fabric composed of the layers of gauze G 1 , G 2 , and G 3  which are laminated together, the warp  3  (or the warp  4 ) is entwined with the weft B (or the weft A) at adequate positions (locations) (see,  FIG. 1 ). In other words, the twisted yarn (warp)  3  of the middle layer G 2  contributes to join the gauze G 2  as the second layer and the gauze G 1  as the first layer together. 
     In the gauze fabric composed of the layers of gauze G 1 , G 2 , and G 3  which are laminated together, the warp  4  (or the warp  3 ) is entwined with a weft F (or a weft E) at adequate positions (locations) (see,  FIG. 1 ). In other words, the twisted yarn (warp)  4  of the middle layer G 2  contributes to join the gauze G 2  as the second layer and the gauze G 3  as the third layer together. 
     The gauze of the present embodiment includes layers which are joined together via the warps (wefts). 
     The gauze G 1  as the first layer, the gauze G 2  as the second layer, and the gauze G 3  as the third layer may be manufactured by a type of weave similar to a weave for manufacturing the conventional triple gauze fabric. As a matter of course, the type of weave is not limited thereto. 
     In the conventional N (N is an integer equal to or greater than 2) gauze fabric, a common type of warp was employed in each layer. To the contrary, in the N (N is an integer equal to or greater than 3) gauze fabric of the present invention, a non-twisted yarn is employed for the first layer (surface layer) and the Nth layer (back layer), and a twisted yarn is employed for at least one middle layer. Therefore, when manufacturing the N (N is an integer equal to or greater than 3) gauze fabric of the present invention, a device capable of supplying at least two different yarns (a non-twisted yarn and a twisted yarn) was used. 
     A triple gauze fabric composed of the warps  1 ,  2 ,  3 ,  4 ,  5 , and  6  and the wefts A, B, C, D, E, and F, the warps and the wefts being a non-twisted yarn, was manufactured as a comparison example 1. 
     A triple gauze fabric composed of the warps  1 ,  2 ,  3 ,  4 ,  5 , and  6  and the wefts A, B, C, D, E, and F, the warps and the wefts being a twisted yarn, was manufactured as a comparison example 2. 
     A triple gauze fabric composed of the warps  1 ,  2 ,  5 , and  6  and the wefts A, B, E, and F, the warps and the wefts being a twisted yarn, and the warps  3  and  4  and the wefts C and D, the warps and the wefts being a non-twisted yarn, was manufactured as a comparison example 3. 
     A triple gauze fabric composed of the warps  1 ,  2 ,  3 , and  4  and the wefts A, B, C, and D, the warps and the wefts being a twisted yarn, and the warps  5  and  6  and the wefts E and F, the warps and the wefts being a non-twisted yarn, was manufactured as a comparison example 4. 
     A sewing ability was compared between the triple gauze fabric of the present embodiment and each of the triple gauze fabrics of the comparison examples 1, 2, 3, and 4. As a result, sewing condition was not good in the triple gauze fabric of the comparison example 1 that was woven with only non-twisted yarns. Only with a small tensile force being applied, garments (clothes) manufactured with the triple gauze fabric of the comparison example 1 were torn in their sewing areas. To the contrary, sewing condition was good in the triple gauze fabric of the present embodiment. More specifically, garments (clothes) manufactured with the triple gauze fabric of the present embodiment were not torn in their sewing areas. Sewing condition was good in each of the triple gauze fabrics of the comparison examples 2, 3, and 4. 
     A feel of touch was compared between the triple gauze fabric of the present embodiment and each of the triple gauze fabrics of the comparison examples 1, 2, 3, and 4. As a result, the triple gauze fabric (in which non-twisted yarns were substantially employed for all the warps and wefts of the surface layer and for all the warps and wefts of the back layer) of the present embodiment was excellent in feel of touch. To the contrary, the triple gauze fabrics of the comparison examples 2, 3, and 4 were degraded in feel of touch and softness in comparison with the triple gauze fabric of the present invention. Only little portions of the twisted yarns  3  and  4  are exposed to the surface (see,  FIG. 1 ). A rate of exposure of the twisted yarns  3  and  4 , however, is almost 0. Therefore, the feel of touch is not degraded. 
     Further, in the triple gauze fabric of the present embodiment, the surface layer (back layer) was composed of non-twisted yarns, and the middle layer was composed of twisted yarns. This made the triple gauze fabric of the present embodiment rich in three-dimensional appearance. This rich in three-dimensional appearance brought about excellent heat-retaining property, softness, and light in weight for its thickness. 
     Hereinabove, a description was made with respect to the triple gauze fabric. The present invention, however, may be an N (N is an integer equal to or greater than 4) gauze fabric. In this case, the surface layer and the back layer are woven with non-twisted yarns, and at least one middle layer is woven with twisted yarns. Alternatively, all the middle layers may be woven with twisted yarns. In a case where the fabric includes two or more middle layers, it is sufficient that at least one middle layer is woven with twisted yarns. However, in a case where the N (N is an integer equal to or greater than 4) gauze fabric including two or more middle layers is compared to the triple gauze fabric, the triple gauze fabric is more excellent in lightness and cost. 
       FIG. 1  is a cross sectional view of the gauze fabric including layers which are joined together via the warps (warp yarns).  FIG. 2  is a cross sectional view of the gauze fabric including layers which are joined together via the wefts (woof). The gauze fabric of  FIG. 1  differs from the gauze fabric of  FIG. 2  only in whether warps are employed for joining or wefts are employed for joining. Structures of the gauze fabric of  FIG. 1  and the gauze fabric of  FIG. 2  are identical to each other except for the above described joining structure. Therefore, a detailed description thereof is omitted here. The joining may be performed via both of warps and wefts. 
     In an example of the gauze fabric of  FIG. 1 , the gauze G 2  and the gauze G 1  are joined with each other, and the gauze G 2  and the gauze G 3  are joined with each other. However, such a structure may be also employed that the surface layer G 1  and the back layer G 3  are directly joined with each other, and thereby the middle layer G 2  between the surface layer G 1  and the back layer G 3  is indirectly joined with them. 
     In  FIG. 1  and  FIG. 2 , the thickness of warps and the thickness of wefts may look different from each other. However, in the above described embodiment, thicknesses of warps and wefts are substantially the same. As a matter of course, the thicknesses may differ from one another. 
     For matters not specifically mentioned, the present invention is interpreted based on the common general knowledge of one skilled in the art. 
     The gauze of present invention is made of only cotton yarn. The cotton yarn is made entirely of cotton fiber. The twisted yarn of present invention is made entirely of cotton fiber. The non-twisted yarn of present invention is made entirely of cotton fiber. 
     The present invention excludes chemical fiber to exclude the risk of allergy. For sensitive skin people, chemical substances cause allergies. 
     The present invention can implement concave and convex appearance (wrinkle) in the surface layer and the back layer without using a chemical yarn (chemical fiber). 
       FIG. 4  shows one of actual product appearance of the present invention. The gauze fabric of the present invention has a wrinkle. The wrinkle (of different color gauze) is enlarged . 
     REFERENCE CHARACTER LIST 
     
         
         G 1  first layer (surface layer) 
         G 2  second layer (middle layer) 
         G 3  third layer (back layer) 
           1 ,  2 ,  5 ,  6  warp (non-twisted yarn: single yarn) 
         A, B, E, F weft (non-twisted yarn: single yarn) 
           3 ,  4  warp (twisted yarn: double yarn) 
         C, D weft (twisted yarn: double yarn)