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  Method for manufacturing fabric structureUSPTO Application #: 20060205305Title: Method for manufacturing fabric structure Abstract: A fabric structure and its manufacturing method are disclosed. The fabric structure is weaved by wefts and warps which are crossed with each other, and each of wefts and warps has a double ply structure in which yarns thereof are contacted in a length direction. The fabric structure gives more excellent mechanical strength and better flexibility than a conventional one. Relatively thicker reinforced weft and warp are repeatedly inserted and weaved among common wefts and warps so as to form repeatedly protruded rectangular patterns on the surface of the fabric structure. The patterns increase a surface friction, thereby preventing accidents caused by slippery of the surface of the fabric structure. (end of abstract) Agent: Jones Day - New York, NY, US Inventor: Dong-Ho Chang USPTO Applicaton #: 20060205305 - Class: 442187000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Including Strand Precoated With Other Than Free Metal Or Alloy The Patent Description & Claims data below is from USPTO Patent Application 20060205305. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a fabric structure and its manufacturing method, and more particularly to a fabric structure made by weaving a plurality of wefts and warps to be crossed with each other, wherein weft and warp respectively have a double ply structure in which warp and weft are contacted in a length direction, and protruded rectangular patterns are repeatedly formed by inserting relatively thicker reinforced wefts and warps among a plurality of common wefts and common warps and then weaving them, and its manufacturing method. [0003] 2. Description of the Related Art [0004] Generally, PE tarpaulin or PVC tarpaulin is commonly used as a textile for waterproof tent, sheltering cover, fabrics for temporary tent, isolating screen in a construction site, and the like. [0005] Among them, PE tarpaulin is generally made by slitting and annealing an HDPE (High-Density Polyethylene) film to make a fabric, and then laminating an LDPE (Low-Density Polyethylene) resin on both surfaces of the fabric. Advantageously, PE tarpaulin does not contain a substance which causes environmental pollution during the manufacturing process, and it is relatively light and recyclable. However, PE tarpaulin has deficient flexibility and low mechanical strength, so its usage is restricted within a very narrow range. [0006] In addition, since PE tarpaulin is apt to be slid by a slight external force due to the nature of the coated LDPE, it is difficult to load products packaged by the tarpaulin in several stages, and workers may be wounded due to its slippery surface. [0007] In order to solve this problem, a tarpaulin in which LDPE resin is multi-coated on a layer weaved by HDPE was disclosed, and recently a method for making a tarpaulin by laminating LDPE resin on one or both surfaces of a layer weaved by HDPE and then extrusion-coating the layer with a cooling roller and a pressing roller was introduced. Such techniques may solve the aforementioned problem to some extent, but they cannot satisfy conditions that it should be more flexible and preserving as an industrial textile and keep a certain mechanical strength. In addition, the above techniques did not solve the problem of slippery. [0008] Thus, researches and developments have been continuously conducted to solve the problems, and the present invention is designed from such technical aspects as a background. SUMMARY OF THE INVENTION [0009] Therefore, an object of the present invention is to provide a fabric structure which is light, malleable and strong rather than a convention one, and is capable of preventing slippery while it is spread on a flat surface. In such an aspect, the present invention provides a fabric structure in which a plurality of wefts and warps are intersectionally weaved to have strong mechanical tenacity and good flexibility, and in which protruded rectangular patterns are repeatedly formed by inserting relatively thicker reinforced wefts and warps among a plurality of common wefts and common warps so as to increase a frictional force and thus prevent slippery. [0010] In order to accomplish the above object, the present invention provides a fabric structure in which a plurality of wefts and warps are weaved to be crossed with each other, wherein each of common wefts and each of common warps, composing the plurality of wefts and warps, are contacted with each other in a length direction. [0011] At this time, each of the common wefts and the common warps preferably has a double ply structure in which sides of yarns thereof are contacted in a length direction. More preferably, the plurality of wefts include a plurality of common wefts and one colored weft, repeatedly arranged in parallel, and the plurality of warps includes a plurality of common warps and one colored warp, repeatedly arranged in parallel. [0012] Alternatively, it is also preferred that the plurality of wefts include a plurality of common wefts and one reinforced weft, repeatedly arranged in parallel, and the plurality of warps includes a plurality of common warps and one reinforced warp, repeatedly arranged in parallel, and the common wefts and the common warps are contacted in length direction. More preferably, the reinforced weft and the reinforced warp are colored. [0013] Meanwhile, the weft and the warp may be yarn made by one selected from the group consisting of polyethylene fiber, polypropylene fiber, polyamide fiber, and polyester fiber. Preferably, a coating layer is coated on one or both surfaces of the fabric structure. More preferably, the fabric structure may be used for a waterproof tent, a sheltering cover, fabrics for a temporary tent, an isolating screen in a construction spot. [0014] In another aspect of the invention, there is provided a method for manufacturing a fabric structure, which includes (a) winding a yarn for weft around a corn; (b) winding a predetermined length of the yarn around a drum of a length measuring machine from the corn; (c) storing the yarn wound around the drum by means of air blown out of a balloon breaker; (d) arranging a plurality of warps in a vertical direction so that the warps are alternately waved; (e) delivering the yarn to a nozzle through an exit of the balloon breaker as much as a predetermined length in succession; and (f) delivering the yarn into a gap between the alternately waved warps twice in succession by discharging a pressing liquid through the nozzle together with the yarn, and delivering the yarn twice in succession therethrough with exchanging an alternately waved pattern of the warps, and then repeating this delivering procedure until the fabric structure is completely weaved. [0015] At this time, in the step (d), a plurality of common warps and one colored warp are preferably repeatedly arranged in parallel in a vertical direction, and, in the steps (e) and (f), an additional length measuring machine is preferably provided for delivering a colored yarn, and a colored yarn may be delivered twice in succession after repeating the processes of delivering the yarn twice in succession and then delivering the yarn twice in succession with exchanging the alternatively waved pattern of the common warps and the colored warp predetermined times, and this delivering procedure is repeated until the fabric structure is completely weaved. [0016] Meanwhile, in the step (d), a plurality of common warps and one reinforced warp may be repeatedly arranged in parallel in a vertical direction, and, in the steps (e) and (f), an additional length measuring machine may be provided for delivering a reinforced weft, and a reinforced weft is delivered twice in succession after repeating the processes of delivering the yarn twice in succession and then delivering the yarn twice in succession with exchanging the alternatively waved pattern of the common warps and the reinforced warp predetermined times, and this delivering procedure is repeated until the fabric structure is completely weaved. [0017] The method for manufacturing a fabric structure may further include (g) coating a coating agent on one or both surfaces of the weaved fabric structure; and (h) extrusion-coating the fabric structure with passing through a cooling roll and a pressing roll. BRIEF DESCRIPTION OF THE DRAWINGS [0018] Other objects and aspects of the present invention will become apparent from the following description of embodiments with reference to the accompanying drawing in which: [0019] FIG. 1a is a perspective view showing a single yarn; [0020] FIG. 1b is a perspective view showing a double ply structure of yarns whose flat surfaces are contacted; [0021] FIG. 1c is a perspective view showing a double ply structure of yarns whose sides are contacted; Continue reading... Full patent description for Method for manufacturing fabric structure Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Method for manufacturing fabric structure patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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