Woven fabric, method for manufacturing design woven fabric and method for manufacturing interior material

Patent metadata

Field	Value
Publication number	US-10145038-B2
Application number	US-201715595121-A
Country	US
Kind code	B2
Filing date	May 15, 2017
Priority date	May 26, 2016
Publication date	Dec 4, 2018
Grant date	Dec 4, 2018

Abstract

A woven fabric which enables protection of optical fiber yarns while the woven fabric is processed into a design woven fabric and easy exposure of the optical fiber yarns when the protection thereof becomes unnecessary, a method for manufacturing a design woven fabric from this woven fabric, and a method for manufacturing an interior material including: A woven fabric having a first constituent yarn having an optical fiber yarn and a non-light guiding yarn and a second constituent yarn having a non-light guiding yarn. The woven fabric having a first region in which the first and second constituent yarns are woven in one layer and a second region which is positioned adjacent to the first region and in which the first and second constituent yarns and are woven in two or more separable layers. The woven fabric has an optical fiber layer and a back protecting layer as the separable layers. The optical fiber layer is a layer formed of the optical fiber yarns. The back protecting layer is a layer in which the non-light guiding yarn of the first constituent yarn and the non-light guiding yarn of the second constituent yarn are woven. Further, the woven fabric can further have a front protecting layer.

First claim

What is claimed is:

1. A woven fabric comprising a first constituent yarn as one of a warp and a weft and a second constituent yarn as the other, wherein
the first constituent yarn has an optical fiber yarn and a non-light guiding yarn other than the optical fiber yarn,
the second constituent yarn has a non-light guiding yarn;
the woven fabric has a first region in which the first and second constituent yarns are woven in one layer and a second region which is positioned adjacent to the first region and in which the first and second constituent yarns are woven in two or more separable layers;
the woven fabric has an optical fiber layer and a back protecting layer as the separable layers;
the optical fiber layer is a layer formed of the optical fiber yarn; and
the back protecting layer is a layer in which the non-light guiding yarn of the first constituent yarn and the non-light guiding yarn of the second constituent yarn are woven.

2. The woven fabric according to claim 1 , wherein
the second region comprises three or more separable layers;
the three layers are a front protecting layer, the optical fiber layer and the back protecting layer in this order; and
the front protecting layer is a layer in which the non-light guiding yarn of the first constituent yarn and the non-light guiding yarn of the second constituent yarn are woven.

3. The woven fabric according to claim 1 , which has the first region, the second region positioned adjacent to the first region, and a third region positioned adjacent to the second region on a side opposite to the first region with the second region being sandwiched between the first and third regions; and
the third region is a region in which the first and second constituent yarns are woven in one layer and which is narrower in width than the second region.

4. The woven fabric according to claim 1 , wherein the non-light guiding yarn of the first constituent yarn has fineness smaller than that of the non-light guiding yarn of the second constituent yarn.

5. A method for manufacturing a design woven fabric using the woven fabric according to claim 1 , the method comprising:
an exposure step of cutting off the back protecting layer to expose the optical fiber layer.

6. The woven fabric according to claim 5 , wherein
the second region comprises three or more separable layers;
the three layers are a front protecting layer, the optical fiber layer and the back protecting layer in this order; and
the front protecting layer is a layer in which the non-light guiding yarn of the first constituent yarn and the non-light guiding yarn of the second constituent yarn are woven.

7. The woven fabric according to claim 5 , which has the first region, the second region positioned adjacent to the first region, and a third region positioned adjacent to the second region on a side opposite to the first region with the second region being sandwiched between the first and third regions; and
the third region is a region in which the first and second constituent yarns are woven in one layer and which is narrower in width than the second region.

8. The woven fabric according to claim 5 , wherein the non-light guiding yarn of the first constituent yarn has fineness smaller than that of the non-light guiding yarn of the second constituent yarn.

9. The method for manufacturing a design woven fabric according to claim 5 , which comprises a heat setting step of heat-setting the woven fabric while protecting the optical fiber layer by the back protecting layer, before the exposure step.

10. The method for manufacturing a design woven fabric according to claim 5 , which comprises a resin coating step of coating the back surface of the woven fabric with a resin while protecting the optical fiber layer by the back protecting layer, before the exposure step.

11. A method for manufacturing an interior material using the woven fabric according to claim 1 , the method comprising:
an exposure step of cutting off the back protecting layer to expose the optical fiber layer; and
a tension-attachment step of tension-attaching a design woven fabric obtained through the exposure step to a surface of a base material part.

12. The woven fabric according to claim 11 , wherein
the second region comprises three or more separable layers;
the three layers are a front protecting layer, the optical fiber layer and the back protecting layer in this order; and
the front protecting layer is a layer in which the non-light guiding yarn of the first constituent yarn and the non-light guiding yarn of the second constituent yarn are woven.

13. The woven fabric according to claim 11 , which has the first region, the second region positioned adjacent to the first region, and a third region positioned adjacent to the second region on a side opposite to the first region with the second region being sandwiched between the first and third regions; and
the third region is a region in which the first and second constituent yarns are woven in one layer and which is narrower in width than the second region.

14. The woven fabric according to claim 11 , wherein the non-light guiding yarn of the first constituent yarn has fineness smaller than that of the non-light guiding yarn of the second constituent yarn.

Assignees

• Toyota Boshoku Kk
• Daiki Kk

Inventors

• Yamada Takamasa
• Okahara Shingo
• Sakoh Mitsutaka
• Kanamori Hideo
• Ito Atsuhiko
• Yamamoto Takayoshi

Classifications

• D03D3/06 Primary

  Fabrics of varying width · CPC title

• G02B6/001

  the light being emitted along at least a portion of the lateral surface of the fibre · CPC title

• G02B6/0005

  the light guides being of the fibre type (G02B6/0003 takes precedence) · CPC title

• D03D11/02

  Fabrics formed with pockets, tubes, loops, folds, tucks or flaps (fabrics consisting of a single tube D03D3/02) · CPC title

• D03D15/00 Primary

  Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used · CPC title