[Technical Field]
[0001] The present invention relates to screen fabrics including a dope dyed fiber, and
more particularly to fabrics that use a dope dyed fiber to eliminate the need for
dyeing, which shortens the production process, and whose discoloration due to post-processing
is minimized.
[Background Art]
[0002] In general, screens are installed in houses, hotels, restaurants and other buildings
to protect people's private lives and block sunlight. Typical screens are produced
by interconnecting a series of metal strips, wood strips or plastic strips at regular
intervals and hanging the interconnected strips down. In recent years, many types
of screen products have emerged in the market. Of these, a representative screen includes
a synthetic resin fabric and a roll. The synthetic resin fabric has a predetermined
width and the roll is fixed to a window. The screen is designed in such a way that
the fabric rolls down to cover the window or rolls up to secure a field of view when
a user rotates the roll. Such screens may be called by different names, such as roll
screens, panel screens or vertical blinds, according to the shape (e.g., roll or panel)
of fabrics employed.
[0003] Conventional screen fabrics are usually made of polyvinyl chloride (PVC). Since PVC
is decomposed by fire to give off chlorine (CI) gas that is very harmful to humans,
the use of PVC as a screen fabric material is prohibited in most countries, including
the United States, Japan and European countries. Under such circumstances, polyethylene
terephthalate (PET) is rapidly replacing PVC as a material for screen fabrics due
to its excellent characteristics in heat resistance, stiffness, electrical properties
and oil resistance. PET is also not susceptible to temperature and humidity variations.
[0004] PET fabrics are dyed after weaving to impart desired colors to final screen products.
[0005] The dyed screen fabrics undergo several post-processing steps, such as cleaning,
antifouling, antistatic, coating, stiffening and heat treatment finishes. These post-processing
steps severely discolor the screen fabrics, and as a result, cause many problems,
such as increased defects and high production costs.
[0006] In attempts to solve the problems associated with the discoloration of screen fabrics,
many dyeing methods have been developed. For example, a method is proposed for weaving
yarn-dyed yarns to produce a dyed fabric. However, this method fails to effectively
protect the fabric from discoloration due to post-processing.
[0007] A woven screen fabric according to the preamble of claim 1 is known from
KR 2002 0 008 287 A.
[Disclosure]
[Technical Problem]
[0008] The present invention has been made in an effort to solve the problems of the prior
art, and it is an object of the present invention to provide a screen fabric that
is produced by weaving a dope dyed fiber spun from a mixture of a dye and polymer
chips in a spinning machine to minimize discoloration due to post-processing while
eliminating the need for dyeing to impart a desired color, thereby reducing the number
of defects and achieving high durability.
[Technical Solution]
[0009] According to an aspect of the present invention, there is provided a screen fabric
for blocking light from a lighting system or sunlight, including a regular fiber and
a dope dyed fiber wherein the dope dyed fiber is directly included in either warps
or wefts or both, or a blended or plied fiber of the regular fiber and the dope dyed
fiber is included in either warps or wefts or both, and wherein differences in the
lightness, chroma and hue of the screen fabric before and after post-processing are
± 2 or less, ± 2 or less and ± 0.1 or less, respectively.
[0010] In an embodiment, the dope dyed fiber is a polyester fiber.
[0011] Either the regular fiber or the dope dyed fiber or both are blended or plied with
a low-melting fiber in a weight ratio of 50:50 to 80:20.
[0012] In an embodiment, the weight ratio of the regular fiber to the dope dyed fiber is
from 20:80 to 80:20.
[0013] According to another aspect of the present invention, there is provided a screen
fabric for blocking light from a lighting system or sunlight, wherein the dope dyed
fiber comprises a flame retardant polyester.
[0014] In an embodiment, the weight ratio of the regular fiber to the flame retardant polyester
dope dyed fiber is from 40:60 to 80:20.
[0015] In an embodiment, the regular fiber is a flame retardant fiber.
[Advantageous Effects]
[0016] The screen fabrics of the present invention show an insignificant degree of discoloration
due to post-processing steps, such as washing, antifouling and heat treatment finishes,
after weaving. Therefore, the number of defects in the screen fabrics is reduced,
leading to high productivity and cost reduction.
[0017] In addition, screens using the screen fabrics of the present invention are not discolored
even after long-term use.
[Best Mode]
[0018] Preferred embodiments of the present invention will now be described in detail. In
describing the present invention, detailed descriptions of related known functions
or configurations are omitted in order to avoid making the essential subject of the
invention unclear.
[0019] The term "fabrics" is used herein to refer to all knitted fabrics, felt fabrics,
plaited fabrics, non-woven fabrics, laminated fabrics, molded fabrics and webs.
[0020] In an embodiment, the present invention provides a screen fabric including a regular
fiber and a dope dyed fiber in a mixed state.
[0021] Any filament fiber composed of a synthetic resin may be used without limitation as
the regular fiber. A flame retardant filament fiber is preferably used to improve
the flame retardancy of the fabric.
[0022] A filament fiber spun from a mixture of a dye and polymer chips in a spinning machine
may be used without any limitation as the dope dyed fiber.
[0023] The dye is dispersed in the polymer chips before spinning into the dope dyed fiber.
The dye is bonded within the fabric to ensure superior light and wash fastness of
the fabric.
[0024] The screen fabric of the present invention may be produced by directly including
the dope dyed fiber in either warps or wefts or both. Alternatively, the screen fabric
of the present invention may be produced by blending or plying the regular fiber with
the dope dyed fiber and including the blended or plied fiber in either warps or wefts
or both.
[0025] Preferably, the dope dyed fiber is composed of a polyester synthetic resin that has
excellent characteristics in terms of heat resistance, stiffness, electrical properties
and oil resistance and is insusceptible to temperature and humidity variations.
[0026] Either the regular fiber or the dope dyed fiber or both may be blended or plied with
a low-melting fiber. The use of the low-melting fiber eliminates the need for additional
coating and imparts stiffness to the screen fabric, thus allowing the screen fabric
to be suitable for use in a screen.
[0027] The blend or ply of the regular fiber and the dope dyed fiber with the low-melting
fiber is in a weight ratio of 50:50 to 80:20.
[0028] The screen fabric undergoes heat treatment to melt-bond the low-melting fiber to
the regular fiber and the dope dyed fiber. This melt-bonding of the low-melting fiber
between the regular fiber and the dope dyed fiber imparts stiffness and shape stability
to the fabric.
[0029] As non-limiting examples of the low-melting fiber, there may be used sheath-core
type and split type conjugate fibers. For example, the low-melting fiber may be a
flame retardant polyester filament in which a low-melting polyester resin is included
in the sheath and a flame retardant polyester resin is included in the core. The flame
retardant polyester resin may be selected from the group consisting of polyethylene
terephthalate, polybutylene terephthalate and a combination thereof. The low-melting
polyester resin may contain isophthalic acid, terephthalic acid, ethylene glycol and
diethylene glycol moieties.
[0030] The flame retardant polyester resin may have a melting point of 220 to 260°C. The
low-melting polyester resin may have a melting point of 110 to 220°C. The polyester
having a melting point lower than 110°C may be problematic in terms of shape stability.
The polyester having a melting point higher than 220°C may adversely affect the resin
of the core.
[0031] The content ratio of the regular fiber and the dope dyed fiber in the screen fabric
may be varied depending on the materials of the regular fiber and the dope dyed fiber
and the desired lightness, chroma and hue differences of the fabric. Most preferably,
the weight ratio of the regular fiber to the dope dyed fiber is from 20:80 to 80:20.
[0032] In another embodiment, the present invention provides a screen fabric including a
regular fiber and a flame retardant polyester dope dyed fiber. The use of the flame
retardant polyester dope dyed fiber imparts flame retardancy to the screen fabric,
thus eliminating the need for additional flameproof finish.
[0033] The regular fiber and the flame retardant polyester dope dyed fiber may be blended
or plied with a low-melting fiber.
[0034] The blend or ply of the regular fiber and the flame retardant polyester dope dyed
fiber with the low-melting fiber is in a weight ratio of 50:50 to 80:20.
[0035] The content ratio of the regular fiber and the flame retardant polyester dope dyed
fiber in the screen fabric may be varied depending on the materials of the regular
fiber and the flame retardant polyester dope dyed fiber and the desired lightness,
chroma and hue differences of the screen fabric. Most preferably, the weight ratio
of the regular fiber to the flame retardant polyester dope dyed fiber is from 40:60
to 80:20.
[0036] Preferably, the flame retardant polyester dope dyed fiber is one that is copolymerized
with a phosphorus flame retardant. The phosphorus flame retardant is preferably present
in an amount such that the concentration of phosphorus (P) atoms in the polyester
resin is from 5,000 to 10,000 ppm. If the content of the phosphorus (P) atoms is less
than 5,000 ppm, sufficient flame retardancy is not exhibited. Meanwhile, if the content
of the phosphorus (P) atoms exceeds 10,000 ppm, the melt viscosity of the polyester
resin is low, resulting in poor workability and physical properties upon spinning.
[0037] The screen fabric may further include at least one additive selected from UV absorbers
and processing aids. The UV absorbers serve to improve the light fastness of the screen
fabric and may be benzotriazole or benzophenone compounds. Examples of processing
aids suitable for use in the screen fabric include antistatic agents, water/oil repellants,
antifouling agents, antibacterial agents, water absorbers and antislip agents, which
are commonly used in the art. It is to be understood that the addition of such well-known
processing aids is encompassed within the scope of the present invention without departing
from the substantial spirit of the invention.
[Mode for Invention]
[0038] The following examples explain methods for producing screen fabrics according to
the present invention and are in no way intended to limit the scope of the present
invention.
EXAMPLES
Example 1
[0039] A regular polyester fiber as warp was woven with a polyester dope dyed fiber as weft
by plain weaving to produce a screen fabric. The screen fabric had a warp density
3937 yarns/m (100 yarns/inch) and a weft density of 3937 yarns/m (100 yarns/inch).
Example 2
[0040] A regular polyester fiber as warp was woven with a plied fiber of a polyester dope
dyed fiber and a regular fiber (1:1 (w/w)) as weft by plain weaving to produce a screen
fabric. The screen fabric had a warp density 3937 yarns/m (100 yarns/inch) and a weft
density of 3937 yarns/m (100 yarns/inch).
Example 3
[0041] A regular polyester fiber as warp was woven with a flame retardant polyester dope
dyed fiber as weft by plain weaving to produce a screen fabric. The screen fabric
had a warp density 3937 yarns/m (100 yarns/inch) and a weft density of 3937 yarns/m
(100 yarns/inch).
Example 4
[0042] A regular polyester fiber as warp was woven with a plied fiber of a flame retardant
polyester dope dyed fiber and a regular fiber (1:1 (w/w)) as weft by plain weaving
to produce a screen fabric. The screen fabric had a warp density 3937 yarns/m (100
yarns/inch) and a weft density of 3937 yarns/m (100 yarns/inch).
Example 5
[0043] A flame retardant regular polyester fiber as warp was woven with a plied fiber of
a polyester dope dyed fiber and a low-melting fiber (1:1 (w/w)) as weft by plain weaving
to produce a screen fabric. The screen fabric had a warp density 3937 yarns/m (100
yarns/inch) and a weft density of 3937 yarns/m (100 yarns/inch).
Example 6
[0044] A regular polyester fiber as warp was woven with a plied fiber of a polyester dope
dyed fiber and a low-melting fiber (1:1 (wlw)) as weft by plain weaving to produce
a screen fabric. The screen fabric had a warp density 3937 yarns/m (100 yarns/inch)
and a weft density of 3937 yarns/m (100 yarns/inch).
Example 7
[0045] A regular polyester fiber as warp was woven with a plied fiber of a flame retardant
polyester dope dyed fiber and a low-melting fiber (1:1 (w/w)) as weft by plain weaving
to produce a screen fabric. The screen fabric had a warp density 3937 yarns/m (100
yarns/inch) and a weft density of 3937 yarns/m (100 yarns/inch).
Example 8
[0046] A flame retardant regular polyester fiber as warp was woven with a plied fiber of
a flame retardant polyester dope dyed fiber and a low-melting fiber (1:1 (w/w)) as
weft by plain weaving to produce a screen fabric. The screen fabric had a warp density
3937 yarns/m (100 yarns/inch) and a weft density of 3937 yarns/m (100 yarns/inch).
[0047] ![](https://data.epo.org/publication-server/image?imagePath=2012/39/DOC/EPNWB1/EP09178441NWB1/imgb0001)
Test Methods
- 1. Discoloration experiments on the screen fabrics of Examples 1-5 after post-processing
After each of the screen fabrics produced in Examples 1-5 was subjected to washing
and antifouling finishes, the degree of discoloration of the screen fabric before
and after the post-processing steps was measured using a computer color match (C.C.M)
system in terms of lightness, chroma and hue differences. Table 1 summarizes the degree
of discoloration after the washing finish and Table 2 summarizes the degree of discoloration
after the antifouling finish.
[0048] The washing and antifouling finishes were carried out by known methods.
TABLE 1
Properties |
Lightness difference |
Chroma difference |
Hue difference |
Example 1 |
-0.82 |
1.08 |
0.08 |
Example 2 |
-0.76 |
0.93 |
0.07 |
Example 3 |
-0.99 |
1.23 |
0.07 |
Example 4 |
-0.89 |
0.96 |
0.06 |
Example 5 |
-0.88 |
1.11 |
0.08 |
TABLE 2
Properties |
Lightness difference |
Chroma difference |
Hue difference |
Example 1 |
-1.42 |
1.49 |
0.09 |
Example 2 |
-1.34 |
1.28 |
0.08 |
Example 3 |
-1.78 |
1.54 |
0.08 |
Example 4 |
-1.44 |
1.49 |
0.08 |
Example 5 |
-1.32 |
1.67 |
0.09 |
2. Discoloration experiments on the screen fabrics of Examples 6-8 after post-processing
[0049] After each of the screen fabrics produced in Examples 6-8 was subjected to washing,
antifouling and heat treatment finishes, the degree of discoloration of the screen
fabric before and after the respective processing steps was measured in terms of lightness,
chroma and hue differences. The heat treatment finish is a post-processing step to
melt-bond the low-melting fiber to the regular fiber and the dope dyed fiber. Table
3 summarizes the degree of discoloration after the washing finish, Table 4 summarizes
the degree of discoloration after the antifouling finish, and Table 5 summarizes the
degree of discoloration after the heat treatment finish.
[0050] The washing and antifouling finishes were carried out by known methods, and the heat
treatment finish for melt-bonding was carried out at 170°C.
TABLE 3
Properties |
Lightness difference |
Chroma difference |
Hue difference |
Example 6 |
-0.84 |
1.52 |
0.08 |
Example 7 |
-0.96 |
1.67 |
0.09 |
Example 8 |
-0.92 |
1.55 |
0.09 |
TABLE 4
Properties |
Lightness difference |
Chroma difference |
Hue difference |
Example 6 |
-1.39 |
1.71 |
0.08 |
Example 7 |
-1.53 |
1.81 |
0.08 |
Example 8 |
-1.47 |
1.70 |
0.09 |
TABLE 5
Properties |
Lightness difference |
Chroma difference |
Hue difference |
Example 6 |
-1.92 |
1.87 |
0.08 |
Example 7 |
-1.97 |
1.69 |
0.09 |
Example 8 |
-1.90 |
1.67 |
0.09 |
[0051] As can be seen from the experimental results in Tables 1-5 showing the discoloration
differences of the screen fabrics of Examples 1-8, the lightness, chroma and hue differences
of each of the screen fabrics before and after the post-processing steps were ± 2
or less, ± 2 or less and ± 0.1 or less, respectively, indicating that little discoloration
of the screen fabrics was caused by the post-processing steps.
[0052] Although the present invention has been described herein with reference to the foregoing
embodiments, the scope of the present invention is not limited to the embodiments.
Therefore, it will be evident to those skilled in the art that various substitutions,
modifications and changes are possible, within the scope of the accompanying claims.
1. A woven screen fabric for blocking light from a lighting system or sunlight comprising
a regular fiber and a dope dyed fiber wherein the dope dyed fiber is directly included
in either warps or wefts or both, or a blended or plied fiber of the regular fiber
and the dope dyed fiber is included in either warps or wefts or both, and wherein
differences in the lightness, chroma and hue of the screen fabric before and after
post-processing are ± 2 or less, ± 2 or less and ± 0.1 or less, respectively,
characterized in
that either the regular fiber or the dope dyed fiber or both are blended or plied with
a low-melting fiber in a weight ratio of 50:50 to 80:20 and wherein the post-processing
is selected from the group consisting of washing, antifouling and heat treatment finishes,
and performed after wearing.
2. The screen fabric of claim 1, wherein the dope dyed fiber is a polyester fiber.
3. The screen fabric of claim 1 or 2, wherein the weight ratio of the regular fiber to
the dope dyed fiber is from 20:80 to 80:20.
4. The screen fabric according to one of the claims 1 to 3, wherein the dope dyed fiber
comprises a flame retardant polyester.
5. The screen fabric of claim 4, wherein the weight ratio of the regular fiber to the
flame retardant polyester dope dyed fiber is from 40:60 to 80:20.
6. The screen fabric according to one of the claims 1 to 5, wherein the regular fiber
is a flame retardant fiber.
1. Abschirmgewebe zum Blockieren von Licht von einem Beleuchtungssystem oder Sonnenlicht,
das eine normale Faser und eine düsengefärbte Faser umfasst, wobei die düsengefärbte
Faser direkt entweder in Kettfäden oder Schussfäden oder beiden enthalten ist, oder
eine aus der normalen Faser und der düsengefärbten Faser gemischte oder gezwirnte
Faser entweder in Kettfäden oder Schussfäden oder beiden enthalten ist, und Unterschiede
hinsichtlich Helligkeit, Farbsättigung und Farbton des Abschirmgewebes vor und nach
Nachbearbeitung ± 2 oder weniger, ± 2 oder weniger und ±0,1 oder weniger betragen,
dadurch gekennzeichnet, dass
entweder die normale Faser oder die düsengefärbte Faser oder beide mit einer niedrig
schmelzenden Faser in einem Gewichtsverhältnis von 50:50 bis 80:20 gemischt oder gezwirnt
wird/werden, und wobei die Nachbearbeitung aus der Gruppe ausgewählt wird, die aus
Waschen, Antifouling- und Wärmebehandlungsveredelung besteht, und sie nach dem Weben
durchgeführt wird.
2. Abschirmgewebe nach Anspruch 1, wobei die düsengefärbte Faser eine Polyesterfaser
ist.
3. Abschirmgewebe nach Anspruch 1 oder 2, wobei das Gewichtsverhältnis der normalen Faser
zu der düsengefärbten Faser von 20:80 bis 80:20 reicht.
4. Abschirmgewebe nach einem der Ansprüche 1 bis 3, wobei die düsengefärbte Faser ein
flammhemmendes Polyester umfasst.
5. Abschirmgewebe nach Anspruch 4, wobei das Gewichtsverhältnis der normalen Faser zu
der düsengefärbten Faser aus flammhemmendem Polyester von 40:60 bis 80:20 reicht.
6. Abschirmgewebe nach einem der Ansprüche 1 bis 5, wobei die normale Faser eine flammhemmende
Faser ist.
1. Tissu tissé pour écran pour bloquer la lumière provenant d'un système d'éclairage
ou du soleil, comprenant une fibre normale et une fibre teinte dans la masse, étant
précisé que la fibre teinte dans la masse est incluse directement dans les fils de
chaîne ou de trame ou les deux, ou qu'une fibre mélangée ou retorse de la fibre normale
et de la fibre teinte dans la masse est incluse dans les fils de chaîne ou de trame
ou les deux, et que les différences de luminance, de chroma et de teinte du tissu
pour écran, avant et après le post-traitement, sont de ± 2 ou moins, ± 2 ou moins
et ± 0,1 ou moins, respectivement,
caractérisé en ce que la fibre normale ou la fibre teinte dans la masse ou les deux sont mélangées ou retordues
avec une fibre à bas point de fusion, dans un rapport de poids de 50:50 à 80:20, et
étant précisé que le post-traitement est choisi dans le groupe constitué par le lavage,
le traitement antisalissure et les finitions par traitement thermique, et est réalisé
après le tissage.
2. Tissu pour écran selon la revendication 1, étant précisé que la fibre teinte dans
la masse est une fibre de polyester.
3. Tissu pour écran selon la revendication 1 ou 2, étant précisé que le rapport de poids
de la fibre normale sur la fibre teinte est de 20:80 à 80:20.
4. Tissu pour écran selon l'une des revendications 1 à 3, étant précisé que la fibre
teinte dans la masse comprend un polyester retardateur de flamme.
5. Tissu pour écran selon la revendication 4, étant précisé que le rapport de poids de
la fibre normale sur la fibre teinte dans la masse avec le polyester retardateur de
flamme est de 40:60 à 80:20.
6. Tissu pour écran selon l'une des revendications 1 à 5, étant précisé que la fibre
normale est une fibre retardatrice de flamme.