JP4323164B2 - 3D solid knitting - Google Patents

Description

【００４１】
【発明の効果】
本発明の立体編物は反発感のあるクッション性を有し、表側編地表面はモノフィラメント糸によるざらつき感とギラツキが抑えられ、滑らかな肌触りを有するものである。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to cushion materials for seat sheets for automobiles, railway vehicles, aircraft, child seats, strollers, wheelchairs, furniture, offices, bedding, bed pads, mattresses, mats for preventing bedsores, pillows, cushion materials for cushions, etc. It is suitable for spacers, mold retaining materials, cushioning materials, upper materials for shoes, insole materials, supporters and protectors, etc., and has a repulsive cushioning property, and the surface of the monofilament yarn has a soft touch. The present invention relates to a three-dimensional three-dimensional knitted fabric having a good feel and having a feeling of roughness and a glare that the surface of the knitted fabric is shining due to gloss inherent to monofilament yarns.
[0002]
[Prior art]
Three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabrics is used for various cushioning materials by utilizing functions such as cushioning, breathability, heat retention, body pressure dispersibility, etc. Has been used.
These three-dimensional knitted fabrics may be used by being laminated, but when used in a single layer, it is necessary to increase the thickness in order to improve cushioning properties. A thick monofilament yarn is used as the connecting yarn in order to impart a cushioning property with a sense of resilience to a thick three-dimensional knitted fabric.
[0003]
However, the three-dimensional knitted fabric using a thick monofilament yarn for the connecting yarn has a thick monofilament yarn protruding on the surface of the three-dimensional knitted fabric, which is rough and unpleasant to the touch. It had the problem that it looked bad.
Patent Document 1 discloses a three-dimensional knitted fabric that uses a relatively thick monofilament yarn as a connecting yarn, has a firmness, does not have a feeling of bottoming, and has a good tactile feel and texture. Since the surface knitted fabric is formed of a large pore structure such as a mesh or tricot, resistance is generated in the through-hole portion, and a smooth surface texture cannot be obtained.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 2001-234456
[Problems to be solved by the invention]
The present invention provides a three-dimensional knitted fabric that solves the above-described problems and suppresses the feeling of roughness and glare caused by the monofilament yarn, and has a smooth feel, especially in a three-dimensional knitted fabric that uses a thick monofilament yarn as a connecting yarn to increase the resilience. The purpose is to do.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the present inventor has intensively studied the yarn constituting the front knitted fabric of the three-dimensional knitted fabric, the yarn constituting the connecting yarn, the surface state of the three-dimensional knitted fabric, etc. The present invention has a dense knitting structure formed by yarns, uses synthetic fiber monofilament yarns as connecting yarns, and designs the relationship between the appearance ratio of the multi-yarn and monofilament yarns on the surface of the front knitted fabric and the yarn diameter within a specific range. As a result, the present invention has been accomplished.
[0007]
That is, the present invention
1. A three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and a connecting yarn of 110 dtex or more synthetic fiber monofilament yarns connecting the two layers of knitted fabric, and the front side knitted fabric is formed with multi-yarns The ratio of the appearance area A of the monofilament yarn of the front side knitted fabric and the appearance area B of the multi yarn is expressed by the equation (1), and the diameter D of the monofilament yarn in the same stitch Three-dimensional solid knitted fabric A / B ≦ 0.15, characterized in that the relationship of the apparent diameter MD of the multi-yarn is expressed by equation (2)
MD / D ≧ 1.2 (2)
2. The cushion for bedding comprising the three-dimensional knitted fabric according to 4.1 or 2 comprising the three-dimensional knitted fabric according to 1 or 2 characterized in that the multi yarn is a bulky yarn. It is a material.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
In the three-dimensional knitted fabric of the present invention, a synthetic fiber monofilament yarn of 110 dtex or more is used as a connecting yarn in order to impart a cushioning property with a repulsive feeling. When the monofilament yarn is less than 110 decitex, when the thickness of the three-dimensional knitted fabric is increased, a cushioning property having a repulsive feeling cannot be obtained.
[0009]
Here, as a fiber material used for the connecting yarn, any synthetic fiber such as polytrimethylene terephthalate fiber, polyethylene terephthalate fiber, polybutylene terephthalate fiber, polyamide fiber, polypropylene fiber, polyvinyl chloride fiber, polyester elastomer fiber is used. However, it is preferable to use polytrimethylene terephthalate fiber or polybutylene terephthalate fiber in order to have a cushioning property with elasticity and improve the durability of the cushioning property.
[0010]
Furthermore, the three-dimensional knitted fabric of the present invention needs to be composed of a dense structure with multi-yarn used as the yarn forming the front knitted fabric and an open area ratio of 35% or less. The open area ratio is preferably 25% or less, more preferably 10% or less. The hole area ratio here refers to the area ratio of the holed portion in the layer forming the knitted fabric surface. Conventional three-dimensional knitted fabrics generally have a knitted structure such as a mesh with a large porosity, and have improved the cool feeling by utilizing the air permeability. However, in the present invention, the porosity can be suppressed to 35% or less. It is necessary and a dense knitted structure is extremely important for making the surface feel smooth.
[0011]
In order to make the surface knitted fabric of a three-dimensional knitted fabric a dense knitted structure with an open area ratio of 35% or less, a structure that is dense and does not have an opening, such as a half structure, a back half structure, a quinds cord structure, a sharkskin structure, etc. It is preferable to form the knitted fabric with the appropriate conditions such as the fineness of the multi-yarn used for the front side knitted fabric when knitting the three-dimensional knitted fabric, the knitting machine gauge, the on-machine course, and the width of the finishing process. It can be made 35% or less. The surface may have systematic unevenness, but a flat knitted structure is more preferable for improving smooth touch. The back side knitted fabric may be a knitted fabric having a plurality of openings such as a quadrangular or hexagonal mesh knitted fabric, a marquisette knitted fabric, etc., which may improve lightness and air permeability, and should be formed with an arbitrary knitted structure Can do.
[0012]
The multi yarn forming the front side knitted fabric is a fiber in which single fibers converge and gather in an untwisted or twisted state, such as a multifilament yarn and a spun yarn. The types of fibers include synthetic fibers such as polyester fibers, polyamide fibers, polyacrylic fibers, and polypropylene fibers, natural fibers such as cotton, linen, and wool, recycled fibers such as cupra rayon, viscose rayon, and lyocell. However, it is preferable to use polytrimethyl terephthalate fiber in order to improve the feel of the three-dimensional knitted fabric. In order to make the feel of the knitted fabric surface softer, the multi yarn is preferably a bulky yarn. Examples of the bulky yarn include a yarn imparted with bulkiness, such as false twisted yarn, jet stuffer processed yarn, indented yarn, spun yarn, fluid jet yarn having looped fluff, and the like. If the yarn forming the front side knitted fabric is a multi yarn, the yarn forming the back side knitted fabric may be a multi yarn or a monofilament yarn, and any kind of fiber may be used.
[0013]
In the three-dimensional knitted fabric of the present invention, the front knitted fabric includes a multi-filament constituting the knitted fabric and a monofilament yarn that is a connecting yarn. In order to suppress the roughness of the monofilament yarn and glare due to gloss, The ratio of the appearing area A of the monofilament yarn and the appearing area B of the multi-yarn needs to be A / B ≦ 0.15. More preferably, 0 ≦ A / B ≦ 0.10, more preferably 0 ≦ A / B ≦ 0.05, and closer to 0.
The ratio of the appearance area A of the monofilament yarn of the front side knitted fabric and the appearance area B of the multi-yarn means the area ratio of each yarn that appears in the unit area of the knitted fabric surface, and is measured by the following method.
[0014]
An enlarged photograph (5 to 50 times) of a 1cm square knitted fabric surface is taken from a right angle in a three-dimensional knitted fabric, and the photograph is read into a computer by an image scanner, and a high-definition image analysis system IP1000PC (trade name, Asahi Kasei Corporation) The area of the monofilament yarn and the multi-yarn that can be seen on the surface of the knitted fabric is respectively designated by using the image analysis software of the company), and the area ratio of each designated area is calculated by the ratio of the number of pixels.
When the ratio of the appearance area A of the monofilament yarn and the appearance area B of the multi-yarn on the surface of the knitted fabric is A / B> 0.15, the surface glare and roughness cannot be suppressed. In particular, a dense knitting structure with a small hole area ratio is more prominent in glare of monofilament yarns than a knitted structure with a high hole area ratio such as a mesh, and therefore the A / B ratio needs to be kept smaller than that of the mesh structure.
[0015]
In order to make the area ratio A / B ≦ 0.15, the fineness of the multifilament is larger than the fineness of the monofilament yarn, the feeding tension of the monofilament yarn is larger than the feeding tension of the multifilament, Supply yarn on the overfeed side from the normal feed rate, increase the number of multi yarn filaments, and if warp knitting, feed the monofilament yarn and the needle of the multi yarn at least in the same direction Knit by such a method. More preferably, the overlapping direction of the multi yarn is the same as that of the monofilament yarn, and another multi yarn is overlapped from the opposite direction.
[0016]
In order to cover the monofilament yarn forming the front stitch of the three-dimensional knitted fabric with multi-yarns uniformly and uniformly, and to suppress the feeling of roughness and glare on the surface of the knitted fabric, the same surface knitted fabric satisfying A / B ≦ 0.15 When the diameter of the monofilament yarn in the stitch is D (mm), the apparent diameter of the multi yarn is MD (mm), and the single yarn diameter of the multi yarn is d (mm), MD / D ≧ 1.2 is necessary.
More preferably, MD / D is 2.50 ≧ MD / D ≧ 1.3, and further preferably 2.50 ≧ MD / D ≧ 1.35.
In the case of MD / D <1.2, the uniform coverage of the monofilament yarn by the multi-yarn is lowered, and it is not possible to suppress the rough feeling of the knitted fabric surface and the glare due to the gloss, and also the smooth surface feel I can't get it.
The diameter D of the monofilament yarn is a diameter calculated by the following formula based on the fineness T ₀ (decitex) and the specific gravity ρ ₀ of the monofilament yarn. Even when the monofilament yarn is not a perfect circle, the monofilament yarn is regarded as a perfect circle and is calculated by this formula.
D (mm) = 20 × {T ₀ / (ρ ₀ × π × 1000000)} ^0.5
The apparent diameter MD of the multi-yarn is an apparent diameter calculated by the following formula based on the total fineness T ₁ (decitex) and the specific gravity ρ ₁ of the multi-yarn forming one stitch. In the case where the yarns are formed from multiple types of multi-yarns, the total fineness of two or more types of multi-yarns is calculated based on the fineness and the average specific gravity.
MD (mm) = 20 × {T ₁ / (ρ ₁ × π × 1000000)} ^0.5
The stitches satisfying MD / D ≧ 1.2 may be 40% or more of all stitches of the front side knitted fabric, more preferably 50% or more, and still more preferably 70% or more.
[0017]
In the present invention, the cross-sectional shape of the single yarn of the multi-yarn is a round shape, a triangular shape, an L shape, a T shape, a Y shape, a W shape, a I shape, an eight leaf shape, a flat shape, a dogbone shape, etc. Any shape such as a hollow type or an indeterminate shape can be used, but in order to increase the coverage of monofilament yarn on the surface of the knitted fabric and suppress the feeling of roughness and glare, W type, I type, dog A flat cross section such as a bone shape is more preferable.
The three-dimensional knitted fabric of the present invention can be knitted with a knitting machine having two opposite rows of needle beds, and can be knitted with a double raschel knitting machine, a double circular knitting machine, a flat knitting machine with a V bed, etc. In order to obtain a high-quality three-dimensional knitted fabric, it is preferable to use a double Russell machine. The gauge of the knitting machine is preferably 9-22 gauge.
[0018]
Regarding the density of the connecting yarn, the number of connecting yarns in the area of the solid knitted fabric 6.45 cm ² is N (lines / 6.45 cm ² ), the decitex of the connecting yarn is D (g / 1 × 10 ⁶ cm), and the connecting yarns are connected. When the specific gravity of the yarn is ρ ₀ (g / cm ³ ), the total cross-sectional area (ND · D / 1 × 10 ⁶ · ρ ₀ ) of the connecting yarn in the area of the solid knitted fabric 6.45 cm ² is 0.03. is preferably ~0.35cm ^2, more preferably 0.05~0.25cm ^2. By setting within this range, the three-dimensional knitted fabric has a good cushioning property with a more appropriate rigidity.
[0019]
The connecting yarn may be formed in loop-like stitches in the front and back knitted fabrics, or may have a structure in which it is hooked on the front and back knitted fabrics in an inserted or tacky structure, but at least two connecting yarns are knitted on the front and back sides. In order to improve the form stability of the three-dimensional knitted fabric, it is preferable that the ground is inclined obliquely in opposite directions and connected in a cross shape (X shape) or a truss shape. As used herein, the two connecting yarns may be one in which one connecting yarn is folded back on the front or back knitted fabric and looks like two.
[0020]
The fineness of the fibers used in the three-dimensional knitted fabric of the present invention is usually 100 to 2000 decitex thick, and the number of filaments is arbitrarily set for the multi yarn constituting at least one of the front and back knitted fabrics. it can. As the connecting filament monofilament yarn, one having a thickness of 110 to 1500 dtex can be used. The thickness of the monofilament is preferably 200 to 1000 dtex, more preferably 280 to 900 dtex, from the viewpoint of further suppressing the roughness of the surface of the three-dimensional knitted fabric and imparting a cushioning property with better rebound.
[0021]
The thickness and basis weight of the three-dimensional knitted fabric can be arbitrarily set according to the purpose, but the thickness is preferably 4 to 30 mm, and more preferably 6 to 15 mm. If it is less than 4 mm, the cushioning property tends to be lowered, and if it exceeds 30 mm, it is difficult to finish the three-dimensional knitted fabric. The basis weight is preferably 200 to 3000 g / m ² , more preferably 300 to 2000 g / m ² . The finishing method of the three-dimensional knitted fabric can finish the raw machine through processes such as scouring, dyeing, and heat setting. However, it is preferable to use a stock solution colored yarn for the front and back of the three-dimensional knitted fabric and / or the connecting yarn because the dyeing process can be simplified. . In addition, since the monofilament yarn is relaxed when the raw machine is refined immediately and it is easy to jump out to the surface of the knitted fabric, it is preferable that the fresh machine is first subjected to dry heat setting.
[0022]
Hereinafter, the present invention will be specifically described with reference to Examples.
The method for measuring the performance of the three-dimensional knitted fabric is as follows.
(1) Place the solid knitted fabric after the rebound feeling finish on the table, hold the solid knitted fabric with the fingertips (3 pieces) from above, and evaluate the rebound feeling in the following four stages by sensory evaluation.
◎: Rebound feeling is high ○: Rebound feeling is slightly high △: Rebound feeling is low ×: There is almost no rebound feeling [0023]
(2) Touch (feeling of roughness)
The surface of the three-dimensional knitted fabric is lightly touched with a fingertip, and the roughness of the monofilament yarn on the surface is evaluated in the following four stages by sensory evaluation.
[0024]
◎: No rough feeling ○: Little rough feeling △: Rough feeling is slightly strong ×: Strong rough feeling [0025]
(3) Touch (smoothness)
The surface of the three-dimensional knitted fabric is lightly slid over the entire palm, and the smoothness of the surface is evaluated by the following four steps by sensory evaluation.
◎: Very smooth ○: Slightly smooth △: Slightly lacking ×: No smoothness [0026]
(4) The surface of the glittering three-dimensional knitted fabric is evaluated by the following four stages by appearance evaluation.
◎: Little glare ○: Little glare △: Glare is slightly intense ×: Glare is severe [0027]
[Example 1]
Using a 14-gauge, 13-mm double raschel machine equipped with six rivets, a 167 dtex 96-filament polyethylene terephthalate (PET) false twisted yarn (black dyed yarn) from the heel (L1) forming the front knitted fabric ) From the ridges (L2, L3) forming the front side knitted fabric and the ridges (L5, L6) forming the back side knitted fabric, and 334 decitex / 192 filament polyethylene terephthalate fiber false twisted yarn (polyethylene terephthalate fiber temporary yarn) Twisted yarn 167 decitex 96 filament black pre-dyed yarns are supplied in an all-in arrangement to form a connecting yarn from 筬 (L4) to 390 decitex polytrimethylene terephthalate (PTT) monofilament yarn Is supplied in an all-in arrangement and driven 13.5 courses / In .54Cm, the front and back of the connecting yarn in knitting structure shown below to form a partially cross-structure (× structure) knitted flat solid knitted fabric. The obtained three-dimensional knitted fabric was heat-dried at 170 ° C. for 2 minutes to obtain a three-dimensional knitted fabric having the physical properties shown in Table 1.
[0028]
(Knitting organization)
L1: 2322/101 /
L2: 1011/2322 /
L3: 1000/0111 /
L4: 1043/6734 /
L5: 1110/0001 /
L6: 2210/2234 /
[0029]
[Example 2]
In Example 1, a three-dimensional knitted fabric having physical properties shown in Table 1 was obtained in the same manner as in Example 1 except that 390 decitex polyene terephthalate monofilament yarn was supplied from the ridge (L4) forming the connecting yarn.
[0030]
[Example 3]
In Example 1, a three-dimensional knitted fabric having the physical properties shown in Table 1 was obtained in the same manner as in Example 1 except that the ridges forming the front side knitted fabric were only L2 and L3.
[0031]
[Example 4]
Using a 14-gauge, 13-mm double raschel machine equipped with 6 sheets of reeds, 668 dtex from the reeds (L1, L2) forming the front knitted fabric and the reeds (L5, L6) forming the back knitted fabric / 384 filament polyethylene terephthalate fiber false twisted yarn (polyethylene terephthalate fiber false twisted yarn 167 decitex 96 filament black pre-dyed yarn), L1, L5 guide in 3 in 3 out arrangement, L2, 390 decitex polytrimethylene terephthalate monofilament yarns are fed to the L6 guide in a 3 out 3 in array and fed into the L4 guide from the heels (L3, L4) that form the connecting yarn. Supplied in a 3-out 3-in array, driven 13.5 course / 2.54cm, braided as shown below In connection yarns to form a partially cross-structure (× structure) were organized three-dimensional knitted fabric having a slight opening on the front and back. The obtained three-dimensional knitted fabric was heat-dried at 170 ° C. for 2 minutes to obtain a three-dimensional knitted fabric having the physical properties shown in Table 1.
[0032]
(Knitting organization)
L1: 1022/4355/6755/3422 /
L2: 6755/3422/1022/4355 /
L3: 1010/4343/6767/3434 /
L4: 6767/3434/1010/4343 /
L5: 2210/2243/5567/5534 /
L6: 5567/5534/2210/2243 /
[0033]
[Example 5]
In Example 4, a polybutylene terephthalate (PBT) monofilament yarn of 390 dtex was used as the connecting yarn, and the L1, L3, and L5 guides were arranged in 2 in 2 out, and the L2, L4, and L6 guides were arranged in 2 out and 2 in. A solid knitted fabric having the physical properties shown in Table 1 was obtained in the same manner as in Example 4 except that the following knitted fabric was supplied. (Knitting organization)
L1: 1011/3233/4544/2322 /
L2: 4544/2322/1011/3233 /
L3: 1010/3232/4545/2323 /
L4: 4545/2323/1010/3232 /
L5: 2210/1132/3345/4423 /
L6: 3345/4423/2221/1132 /
[0034]
[Example 6]
In Example 1, a 167 dtex / 96 filament polyethylene terephthalate fiber false twisted yarn (black dyed yarn) is formed from three ridges (L1, L2, L3) forming the front knitted fabric to form a connecting yarn. A solid knitted fabric having the physical properties shown in Table 1 was obtained in the same manner as in Example 1 except that polytrimethylene terephthalate monofilament yarn 280 dtex was supplied from the kite (L4).
[0035]
[Comparative Example 1]
Using a 14-gauge double raschel machine equipped with 6 ridges and a 13 mm gap between the hooks, two ridges (L1, L2) forming the knitted fabric on the front side and two ridges (L5, L2) forming the knitted fabric on the back side L6) to 668 dtex / 384 filament polyethylene terephthalate fiber false twisted yarn (polyethylene terephthalate fiber false twisted yarn 167 decitex 96 filament black pre-dyed yarn) L3, L4) to 390 decitex polytrimethylene terephthalate monofilament yarns are fed in 1 in 1 out arrangement to L1, L3, L5 guides and in 1 out 1 in arrangement to L2, L4, L6 guides and driven 13 .5 course / 2.54 cm, the connecting yarn partially forms a cross structure (x structure) with the following knitting structure It was to organize the three-dimensional knitted fabric on the back mesh. The obtained three-dimensional knitted fabric was widened at 170 ° C. × 2 minutes and heat-set by heat to obtain a three-dimensional knitted fabric having the physical properties shown in Table 1.
[0036]
(Knitting organization)
L1: 1011/1211/1011/1211/1011/1222 /
2322/2122/2322/2122/2322/21111 /
L2: 2322/2122/2322/2122/2322/21111 /
1011/1211/1011/1211/1011/1222 /
L3: 2121/2323/2121/4545/2121/2323 /
3434/3232/3434/1010/3434/3232 /
L4: 3434/3232/3434/1010/3434/3232 /
2121/2323/2121/4545/2121/2323 /
L5: 1110/1112/1110/1112/1110/1112 /
2223/2221/2223/2221/2223/2221 /
L6: 2223/2221/2223/2221/2223/2221 /
1110/1112/1110/1112/1110/1112 /
[0037]
[Comparative Example 2]
In Example 1, except that 167 dtex / 30 filament polyethylene terephthalate fiber false twisted yarn was supplied from three ridges (L1, L2, L3) forming the front side knitted fabric, in the same manner as in Example 1. A three-dimensional knitted fabric having the physical properties shown in Table 1 was obtained.
[0038]
[Comparative Example 3]
In Example 5, the same procedure as in Example 5 was conducted, except that polyethylene terephthalate fiber false twisted yarn of 334 dtex / 192 filament was supplied from two ridges (L1, L2) forming the front side knitted fabric. A three-dimensional knitted fabric having a physical property of 1 was obtained.
[0039]
[Comparative Example 4]
In Example 6, a three-dimensional knitted fabric having physical properties shown in Table 1 was obtained in the same manner as in Example 6 except that 100 dtex polytrimethylene terephthalate monofilament yarn was supplied from the ridge (L4) forming the connecting yarn.
[0040]
[Table 1]

[0041]
【The invention's effect】
The three-dimensional knitted fabric of the present invention has a cushioning property with a rebound feeling, and the surface knitted fabric surface has a smooth feel with a feeling of roughness and glare caused by monofilament yarns suppressed.

Claims (4)

A three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and a connecting yarn of 110 to 1500 decitex synthetic fiber monofilament yarns connecting the two layers of knitted fabric, and is in the area of a solid knitted fabric of 6.45 cm ² The total cross-sectional area (N · D / 1 × 10 ⁶ · ρ ₀ ) of the connecting yarn is 0.03 to 0.35 cm ² , and the front knitted fabric is formed of 100 to 2000 decitex polyester fiber multifilament yarn. aperture ratio is 35% or less dense structure, the ratio of revealing the area B of the multifilament yarn and revealing the area a of the monofilament yarn of the front knitted fabric is expressed by equation (1), the monofilament yarn in the same stitch The relationship between the diameter D of the yarn and the apparent diameter MD of the multifilament yarn is expressed by the formula (2).
A / B ≦ 0.15 (1)
MD / D ≧ 1.2 (2) The three-dimensional knitted fabric according to claim 1, wherein the multifilament yarn is a bulky yarn.   The cushion material for seat sheets which consists of a solid knitted fabric of Claim 1 or 2.   A cushion material for bedding comprising the three-dimensional knitted fabric according to claim 1.