Method for manufacturing three-dimensional fabric and three dimensional fabric using the same

Abstract

A method for manufacturing a three-dimensional fabric and a three-dimensional fabric using the same is provided. The method includes the steps of: selecting at least more than one yarn among nylon6, nylon66 and a super high tenacity yarn to be used as a warp yarn and a filling yarn; weaving the selected warp and filling yarns to produce a basis fabric with ripstops; inserting the basis fabric into a dyer and dyeing the basis fabric by providing a predetermined concentration of a dye at a predetermined temperature for a predetermined period, so that a special pattern and a color are expressed on the basis fabric because of a difference in density, material characteristics and thermal transformation temperatures between the warp yarn and the filling yarn; and drying the dyed basis fabric for a predetermined period at room temperature to make the ripstops, the pattern and the color clear without deformation.

1 . A method for manufacturing a three-dimensional fabric, comprising the steps of: 
 selecting at least more than one yarn among nylon6, which is a typical type of nylon, nylon66, which is reinforced nylon, and a super high tenacity yarn to be used as a warp yarn and a filling yarn;    weaving the selected warp and filling yarns to produce a basis fabric on which a plurality of ripstops are formed;    inserting the woven basis fabric into a dyeing machine and dyeing the basis fabric by providing a predetermined concentration of a dye at a predetermined temperature for a predetermined period, so that a special pattern and a color are caused to be presented on the basis fabric because of a difference in density, material characteristics and thermal transformation temperatures between the warp yarn and the filling yarn; and    drying the dyed basis fabric for a predetermined period at room temperature to make the ripstops, the pattern and the color clear without being deformed.    
   
   
       2 . The method of  claim 1 , wherein the weaving of the nylon66 as a warp yarn and the super high tenacity yarn as a filling yarn results in formation of natural pleats on a surface of the basis fabric during the dyeing because of a stretchability difference between the nylon66 and the super high tenacity yarn and a density difference between the ripstops.  
   
   
       3 . The method of  claim 1 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and the super high tenacity yarn and the nylon6 as a filling yarn results in formation of natural diamond-shaped pleats on a surface of the basis fabric during the dyeing because of a stretchability difference between the nylon66, the super high tenacity yarn and the nylon6 and a density difference between the ripstops.  
   
   
       4 . The method of  claim 1 , wherein during the dyeing of the nylon66, the nylon6 and the super high tenacity yarn, a natural two-toned color portion, each portion with a different brightness, is presented on a surface of the basis fabric because of a dyeing time difference between the nylon66, the nylon6 and the super high tenacity yarn.  
   
   
       5 . The method of  claim 1 , wherein the step of dyeing the woven basis fabric comprises the steps of inserting the woven basis fabric into a polyester dyeing machine and dyeing the woven basis fabric at a temperature ranging from approximately 115° C. to approximately 120° C. for approximately 5 hours, wherein during the step of dyeing, the ripstops are caused to get protruded because of a difference in density, material characteristic and thermal transformation temperature between the warp yarn and the filling yarn constructing each individual ripstop, thereby producing uniformly sized ruffle patterns on a surface of the basis fabric.  
   
   
       6 . The method of  claim 1 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and the nylon6 as a filling yarn results in formation of various three-dimensional patterns on a front and a back side of the basis fabric because of a different density, strength, dyeing temperature, thermal transformation temperature and shrinkage level caused by thermal transformation between the nylon66 and the nylon6 during the dyeing of the basis fabric.  
   
   
       7 . The method of  claim 6 , further comprising the step of inserting the basis fabric into a polyester dyeing machine and dyeing the basis fabric at a temperature ranging from approximately 115° C. to approximately 120° C. while adjusting a concentration of a dye, whereby two-toned shadow ripstops, obtained as different brightness is created on the ripstops of the basis fabric, are formed on a surface of the basis fabric.  
   
   
       8 . The method of  claim 7 , wherein shrinkage caused by thermal transformation of the nylon6 and a low level of shrinkage of the nylon66 at high temperature causes formation of square-shaped protrusion patterns with small tucks on the front side of the basis fabric and uniform dot patterns on the back side of the basis fabric in the direction of the warp yarn and the filling yarn.  
   
   
       9 . The method of  claim 6 , further comprising the steps of inserting the basis fabric into a nylon dyeing machine and dyeing the basis fabric at a temperature of approximately 100° C. while adjusting a concentration of a dye, whereby two-toned shadow ripstops, obtained as different brightness is created on the ripstops of the basis fabric, are formed on a surface of the basis fabric.  
   
   
       10 . The method of  claim 9 , wherein shrinkage caused by thermal transformation of the nylon6 and a low level of shrinkage of the nylon66 at high temperature cause formation of uniform square-shaped protrusion patterns on the front side of the basis fabric and protruded dot patterns on the back side of the basis fabric in the direction of the warp yarn and the filling yarn.  
   
   
       11 . The method of  claim 1 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and as a filling yarn results in formation of a special three-dimensional pattern on the basis fabric because of a different density, strength, dyeing temperature, thermal transformation temperature and shrinkage level caused by thermal transformation between the nylon66 and the nylon6 during the dyeing of the basis fabric.  
   
   
       12 . The method of  claim 11 , further comprising the step of inserting the basis fabric into a nylon dyeing machine and dyeing the basis fabric at a temperature of approximately 100° C. for approximately 7 hours with use of a lowly concentrated dye, whereby two-toned color ripstops are formed on the basis fabric because of a difference in dye absorption between the nylon 66 and the nylon6.  
   
   
       13 . The method of  claim 11 , further comprising the step of inserting the basis fabric into a nylon dyeing machine and dyeing the basis fabric at a temperature of approximately 100° C. for approximately 7 hours with use of a highly concentrated dye, whereby uniform plain ripstops are formed on the basis fabric.  
   
   
       14 . The method of  claim 11 , further comprising the step of inserting the basis fabric into a polyester dyeing machine and dyeing the basis fabric at a temperature ranging from approximately 115° C. to approximately 120° C. for approximately 5 hours, whereby protrusion ripstops are formed on the basis fabric as a number of dots are formed individually at crossing points of the warp yarns and the filling yarns.  
   
   
       15 . A three-dimensional fabric, comprising: 
 a warp yarn including at least more than one yarn selected among nylon6, which is a typical type of nylon, nylon66, which is reinforced nylon, and a super high tenacity yarn;    a filling yarn including at least more than one yarn selected among nylon6, nylon66 and a super high tenacity yarn; and    a basis fabric being woven with the warp yarn and the filling yarn, including a plurality of ripstops formed on a surface of the basis fabric and being dyed as the woven basis fabric is inserted into a dyeing machine and dyed at a predetermined temperature for a predetermined period with using a predetermined concentration of a dye, whereby a special pattern and color are caused to be presented on the surface of the basis fabric because of a different density, material characteristics and thermal transformation temperatures between the warp yarn and the filling yarn constructing the ripstops.    
   
   
       16 . The three-dimensional fabric of  claim 15 , wherein the weaving of the nylon66 as a warp yarn and the super high tenacity yarn as a filling yarn results in formation of natural pleats on a surface of the basis fabric during the dyeing because of a stretchability difference between the warp yarn and the filling yarn and a density difference between the ripstops.  
   
   
       17 . The three-dimensional fabric of  claim 15 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and the super high tenacity yarn and the nylon6 as a filling yarn results in formation of natural diamond-shaped pleats on a surface of the basis fabric during the dyeing because of a stretchability difference between the warp yarn and the filling yarn and a density difference between the ripstops.  
   
   
       18 . The three-dimensional fabric of  claim 15 , wherein during the dyeing of the warp yarn and the filling yarn, a natural two-toned color portion, each portion with a different brightness, is presented on a surface of the basis fabric because of a dyeing time difference between the warp yarn and the filling yarn.  
   
   
       19 . The three-dimensional fabric of  claim 15 , wherein the basis fabric is inserted into a polyester dyeing machine and dyed, whereby the ripstops get protruded because of a difference in density, material characteristic and thermal transformation temperature between the warp yarn and the filling yarn constructing the individual ripstop, thereby producing uniformly sized ruffle patterns on a surface of the basis fabric.  
   
   
       20 . The three-dimensional fabric of  claim 15 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and the nylon6 as a filling yarn results in formation of various three-dimensional patterns on a front and a back side of the basis fabric because of a different density, strength, dyeing temperature, thermal transformation temperature and shrinkage level caused by thermal transformation between the nylon66 and the nylon6 during the dyeing of the basis fabric.  
   
   
       21 . The three-dimensional fabric of  claim 20 , wherein the basis fabric is inserted into a polyester dyeing machine and dyed, whereby two-toned shadow ripstops, obtained as different brightness is created on the ripstops of the basis fabric, are formed on a surface of the basis fabric.  
   
   
       22 . The three-dimensional fabric of  claim 21 , wherein shrinkage of the nylon6 and a low level of shrinkage of the nylon66 causes formation of squared-shaped protrusion patterns with small tucks on the front side of the basis fabric and uniform dot patterns on the back side of the basis fabric in the direction of the warp yarn and the filling yarn.  
   
   
       23 . The three-dimensional fabric of  claim 20 , wherein the basis fabric is inserted into a nylon dyeing machine and dyed, whereby two-toned shadow ripstops, obtained as different brightness is created on the ripstops of the basis fabric, are formed on a surface of the basis fabric.  
   
   
       24 . The three-dimensional fabric of  claim 23 , wherein shrinkage of the nylon6 and a low level of shrinkage of the nylon66 causes formation of uniform square-shaped protrusion patterns on the front side of the basis fabric and protruded dot patterns on the back side of the basis fabric in the direction of the warp yarn and the filling yarn.  
   
   
       25 . The three-dimensional fabric of  claim 15 , wherein the weaving of the nylon66 and the nylon6 as a warp yarn and as a filling yarn results in formation of a special pattern on the basis fabric because of a different density, strength, dyeing temperature, thermal transformation temperature and shrinkage level caused by thermal transformation between the nylon66 and the nylon6 during the dyeing of the basis fabric.  
   
   
       26 . The three-dimensional fabric of  claim 25 , wherein the basis fabric is inserted into a nylon dyeing machine and dyed with use of a lowly concentrated dye, whereby two-toned color ripstops are formed on the basis fabric because of a difference in dye absorption between the nylon 66 and the nylon6.  
   
   
       27 . The three-dimensional fabric of  claim 25 , wherein the basis fabric is inserted into a nylon dyeing machine and dyed with use of a highly concentrated dye, whereby uniform plain ripstops are formed on the basis fabric.  
   
   
       28 . The three-dimensional fabric of  claim 25 , wherein the basis fabric is inserted into a polyester dyeing machine and dyed, whereby protrusion ripstops are formed on the basis fabric as a number of dots are formed individually at crossing points of the warp yarns and the filling yarns.