Fiber assembly and method for producing fiber assembly

Patent metadata

Field	Value
Publication number	US-12215448-B2
Application number	US-202217700961-A
Country	US
Kind code	B2
Filing date	Mar 22, 2022
Priority date	Apr 23, 2021
Publication date	Feb 4, 2025
Grant date	Feb 4, 2025

Abstract

A fiber assembly includes a support sheet, a warp yarn group in which warp yarns including a polymer material are arranged, and a weft yarn group in which weft yarns including a polymer material are arranged. A surface of the support sheet has been subjected to a release treatment. The warp yarn group and the weft yarn group are on the surface of the support sheet. The warp yarn group and the weft yarn group define contact portion regions and non-contact portion regions. In each of the contact portion regions, one of the warp yarns is integrated with one of the weft yarns. Each of the warp yarns and the weft yarns has a line width of 1 μm to 10 μm, inclusive. One of the contact portion regions has a fiber density which is higher than a fiber density of one of the non-contact portion regions.

First claim

What is claimed is:

1. A fiber assembly comprising:
a support sheet;
a warp yarn group in which warp yarns including a polymer material are arranged; and
a weft yarn group in which weft yarns including a polymer material are arranged,
wherein:
a surface of the support sheet is release treated;
the warp yarn group is on the surface of the support sheet;
the weft yarn group is on the surface of the support sheet;
the warp yarn group and the weft yarn group define contact portion regions and non-contact portion regions;
in each of the contact portion regions, at least one of the warp yarns is integrated with at least one of the weft yarns;
each of the warp yarns has a line width of 1 μm to 10 μm, inclusive;
each of the weft yarns has a line width of 1 μm to 10 μm, inclusive;
at least one of the contact portion regions has a fiber density which is higher than a fiber density of at least one of the non-contact portion regions;
in at least one of the contact portion regions, two of the warp yarns or two of the weft yarns have a spacing of 5 μm or more and 1000 μm or less;
in at least one of the non-contact portion regions, two of the warp yarns or two of the weft yarns have a spacing of 2000 μm or more;
average diameters of portions other than a contact portion in which the at least one of the warp yarns is integrated with the at least one of the weft yarns, are defined as a and b respectively;
an average thickness t of the contact portion is 80% or less of a sum of (a+b); and

in a cross section of the contact portion, the weft yarns extend only in an upward direction above the warp yarns.

2. The fiber assembly according to claim 1 , wherein:
the contact portion regions are first contact portion regions;
the warp yarn group is a first warp yarn group;
the warp yarns of the first warp yarn group are non-oblique warp yarns;
the fiber assembly further comprises a second warp yarn group;
the second warp yarn group includes oblique warp yarns;
the oblique warp yarns are not parallel to the non-oblique warp yarns; and
at least one of the non-contact portion regions includes a second contact portion region in which at least one of the oblique warp yarns is integrated with at least one of the weft yarns.

3. The fiber assembly according to claim 2 , wherein the at least one of the oblique warp yarns includes three or less of the oblique warp yarns.

4. The fiber assembly according to claim 1 , wherein:
the contact portion regions are first contact portion regions;
the weft yarn group is a first weft yarn group;
the weft yarns of the first weft yarn group are non-oblique weft yarns;
the fiber assembly further comprises a second weft yarn group;
the second weft yarn group includes oblique weft yarns;
the oblique weft yarns are not parallel to the non-oblique weft yarns; and
at least one of the non-contact portion regions includes a second contact portion region in which at least one of the oblique weft yarns is integrated with at least one of the warp yarns.

5. The fiber assembly according to claim 4 , wherein the at least one of the oblique weft yarns includes three or less of the oblique weft yarns.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Nakamura Taichi
• Tsukahara Norihito
• Ikeda Kouji

Classifications

• D04H3/14

  with bonds between thermoplastic yarns or filaments produced by welding · CPC title

• D01D5/08

  Melt spinning methods {(D01D5/0023 takes precedence)} · CPC title

• D10B2321/121

  polystyrene · CPC title

• D04H3/005

  Synthetic yarns or filaments (D04H3/013 takes precedence) · CPC title

• D04H3/045

  for net manufacturing · CPC title