JP2004232095A - Corrugated board-like three-dimensional woven fabric having stretchability and method for producing the same - Google Patents
Corrugated board-like three-dimensional woven fabric having stretchability and method for producing the same Download PDFInfo
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- JP2004232095A JP2004232095A JP2003018512A JP2003018512A JP2004232095A JP 2004232095 A JP2004232095 A JP 2004232095A JP 2003018512 A JP2003018512 A JP 2003018512A JP 2003018512 A JP2003018512 A JP 2003018512A JP 2004232095 A JP2004232095 A JP 2004232095A
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Abstract
Description
【0001】
【発明の属する技術分野】
本発明は、表面層と裏面層とが互いに接することなく結接層により連結してなる立体織物であって、表面層、裏面層、結接層が各々織物組織を有し、かつストレッチ性を有するダンボール状立体織物及びその製造方法に関するものである。
【0002】
【従来の技術】
従来より、紙製ダンボール材の構造をならった繊維構造体が知られている。例えば、表面層と裏面層が結接糸で連結された多重立体編物(例えば、特許文献1、特許文献2参照)は、ダンボールニットとも称され、クッション性、断熱性、遮音性などを有するため多方面に用いられている。
【0003】
かかる多重立体編物において、結接糸が織編組織を有せず単に表面層と裏面層を連結しているだけなので、剛性が不十分で厚さ方向に潰れ易いという問題があった。
【0004】
かかる問題点に鑑み、本発明者は先に表面層と裏面層とが織物組織を有する弾性部で連結されたクッション性織物を提案した(特願2002−349630号)。該クッション性織物は、その構造が紙製ダンボール材の構造とほぼ同じであるためクッション性に優れるものである。
【0005】
しかるに、用途によってはストレッチ性を有することが望まれており、クッション性を損なわずにストレッチ性を有するダンボール状立体織物の提案が望まれていた。
【0006】
【特許文献1】
特開平7−316959号公報
【特許文献2】
特開平11−36164号公報
【0007】
【発明が解決しようとする課題】
本発明は、前記従来技術の問題を解消するためになされたものであり、本発明の目的は、クッション性を損なうことなくストレッチ性を有するダンボール状立体織物及びその製造方法を提供することにある。
【0008】
【課題を解決するための手段】
本発明者は、上記の課題を達成するため鋭意検討した結果、織物組織を有する表面層と、織物組織を有する裏面層と、波状に屈曲しかつ織物組織を有する結接層とで構成されるダンボール状立体織物において、表面層と裏面層に、織物組織を構成する経糸または緯糸としてストレッチ糸条を、結接層の屈曲が連続する方向(蛇行の進行方向)に配することにより、所望のダンボール状立体織物が得られることを見出した。そして、さらに鋭意検討を重ねることにより本発明を完成するに至った。
【0009】
かくして、本発明によれば「織物組織を有する表面層と、織物組織を有する裏面層と、波状に屈曲しかつ織物組織を有する結接層とで構成されるダンボール状立体織物であって、前記表面層と裏面層において、織物組織を構成する経糸または緯糸としてストレッチ糸条が、結接層の屈曲が連続する方向に配されてなることを特徴とするストレッチ性を有するダンボール状立体織物。」が提供される。
【0010】
その際、前記のストレッチ糸条としては切断伸度70%以上の弾性糸または該弾性糸を含む複合糸が好適である。
【0011】
また、本発明のダンボール状立体織物の波状に屈曲した結接層において、隣り合う山部の中間に谷部が位置し、かつ隣り合う山部の間隔dが2〜10mmの範囲であると、へたりのない安定したクッション性が得られ好ましい。
【0012】
さらには、本発明のダンボール状立体織物において、ストレッチ性の目安として経方向または緯方向のストレッチ度が10%以上であることが好ましい。
【0013】
本発明のダンボール状立体織物は、表面層を形成する経糸と裏面層を形成する経糸に熱収縮率11%以上のストレッチ糸条を配し、かつ結接層を形成する経糸に熱収縮率10%以下の糸条を配するか、または、表面層を形成する緯糸と裏面層を形成する緯糸に熱収縮率11%以上のストレッチ糸条を配し、かつ結接層を形成する緯糸に熱収縮率10%以下の糸条を配することにより、織物組織を有する表面層と、織物組織を有する裏面層と、表面層と裏面層とを連結しかつ織物組織を有する結接層で構成される3重織物を織成した後、該3重織物に80℃以上の温度で1〜60分間の湿熱処理及び/又は140〜200℃の温度で0.1〜20分間の乾熱処理を施すことにより結接層を波状に屈曲させることを特徴とするストレッチを有するダンボール状立体織物の製造方法により得られる。
【0014】
【発明の実施の形態】
以下に本発明を詳細に説明する。
本発明のダンボール状立体織物は、図1に厚み方向の断面を模式的に示すように、織物組織を有する表面層と、織物組織を有する裏面層と、波状に屈曲しかつ織物組織を有する結接層とで構成される。
【0015】
その際、図1に模式的に示す断面形状は、経糸方向または緯糸方向に同じ位相で連続する。すなわち、結接層が屈曲して連続する方向(蛇行の進行方向)が経糸方向ならば、結接層の山部と谷部は緯糸方向に同じ位相で連続し、逆に、結接層が屈曲して連続する方向が緯糸方向ならば、結接層の山部と谷部は経糸方向に同じ位相で連続する。
【0016】
ここで、表面層と結接層とは結接層の山部で結接され、他方、裏面層と結接層の谷部で結接される。かかる結接層において、前記のように屈曲の進行方向が経糸方向であってもよいし、緯糸方向であってもよい。
【0017】
かかる結接層が経糸方向に屈曲して連続する場合には、少なくとも表面層を形成する経糸と裏面層を形成する経糸にはストレッチ糸条が配される。他方、結接層が緯糸方向に屈曲して連続する場合には、少なくとも表面層を形成する緯糸と裏面層を形成する緯糸にはストレッチ糸条が配される。
【0018】
前記の表面層及び裏面層は、平坦であってもよいし凹凸を有していてもよい。また、結接層は緩やかなカーブで波状に屈曲して蛇行していてもよいし、直線的にジグザグに屈曲していてもよい。
【0019】
その際、波状に屈曲した結接層において、隣り合う山部の中間に谷部が位置し、かつ隣り合う山部の間隔dが2〜10mm(より好ましくは3〜7mm)の範囲であると、へたりにくい安定したクッション性が得られ好ましい。
【0020】
本発明のダンボール状立体織物において、厚みは特に限定されず用途によって適宜選定されるが、1〜10mm(より好ましくは1.5〜7mm)の範囲が好ましい。該厚みが1mmよりも小さいと十分なクッション性が得られない恐れがある。逆に、該厚みが10mmよりも大きいとへたりやすく十分な反撥性が得られない恐れがある。
【0021】
次に、本発明のダンボール状立体織物を構成する各層について説明する。
まず、表面層は織物組織を有し、かつ前記のように経糸または緯糸として少なくとも結接層の屈曲が連続する方向にストレッチ糸条が配される。
【0022】
ここで、本発明でいうストレッチ糸条とは、公知の弾性糸、ポリトリメチレンテレフタレート糸条、若しくはこれらを含む複合糸のことであり、仮撚捲縮加工糸は含まれない。ポリトリメチレンテレフタレート糸条は、テレフタル酸またはテレフタル酸ジメチルに代表されるテレフタル酸の低級アルキルエステルと、トリメチレングリコール(1,3−プロパンジオール)を重縮合させて得られるポリトリメチレンテレフタレートを公知の紡糸方法で紡糸することにより得られる。
【0023】
ストレッチ糸条としては、切断伸度70%以上(より好ましくは110%以上800%以下)の弾性糸または該弾性糸を含む複合糸が特に好適である。
【0024】
かかる弾性糸としては、ポリウレタン系弾性糸やポリエーテルエステル系弾性糸が例示される。特に、ポリエーテルエステルブロック共重合体からなる弾性糸が、耐湿熱性、耐アルカリ性、熱セット性に優れるため好ましく例示される。
【0025】
ここで、ポリエーテルエステルブロック共重合体とは、芳香族ポリエステル単位をハードセグメントとし、ポリ(アルキレンオキシド)グリコール単位をソフトセグメントとする共重合体を意味し、芳香族ポリエステルとしては、酸成分の80モル%以上、好ましくは90モル%以上がテレフタル酸、2,6−ナフタレンジカルボン酸、あるいは4,4’−ジフェニルジカルボン酸から選択される1種の酸成分からなり、グリコール成分の80モル%以上、好ましくは90モル%以上が、1,4−ブタンジオール、エチレングリコール、あるいは1,3−プロパンジオールから選択される1種の低分子量グリコールからなるポリエステルが好ましく用いられる。
【0026】
また、ポリ(アルキレンオキシド)グリコールとしては、ポリエチレングリコール、ポリ(プロピレンオキシド)グリコール、ポリ(テトラメチレンオキシド)グリコールなどが挙げられ、好ましくはポリ(テトラメチレンオキシド)グリコールの単独重合体または前記単独重合体を構成する反復単位の2種以上がランダムまたはブロック状に共重合したランダム共重合体またはブロック共重合体、またはさらに前記単独重合体または共重合体の2種以上が混合された混合重合体が使用される。
【0027】
ここで用いるポリ(アルキレンオキシド)グリコールの分子量は、400〜4000、特に600〜3500が好ましい。平均分子量が400未満では、得られるポリエーテルエステルブロック共重合体のブロック性が低下するため弾性的性能に劣る傾向にあり、平均分子量が4000を越える場合は、生成ポリマーが相分離してブロック共重合体となりがたく、弾性的性能に劣る傾向にある。
【0028】
かかるポリエーテルエステルブロック共重合体は、通常の共重合ポリエステルの製造法にならって製造しうる。具体的には、前記酸成分および/またはそのアルキルエステルと低分子量グリコールおよびポリ(アルキレンオキシド)グリコールを反応器に入れ、触媒の存在下または不存在下でエステル交換反応あるいはエステル化反応を行い、さらには高真空で重縮合反応を行って所望の重合度まで上げる方法である。
【0029】
ストレッチ糸条が前記の弾性糸またはポリトリメチレンテレフタレート糸条を含む複合糸である場合、前記の弾性糸と公知のポリエステルフィラメントとを用いてタスラン加工やインターレース加工などの空気加工、複合仮撚加工、合撚、カバリングなどにより得られる複合糸が、優れた風合いや取り扱い性の点で好適である。
【0030】
前記のストレッチ糸条を形成するポリマーには、本発明の目的を損なわない範囲内で必要に応じて、艶消し剤、微細孔形成剤、カチオン可染剤、着色防止剤、熱安定剤、難燃剤、蛍光増白剤、着色剤、帯電防止剤、吸湿剤、抗菌剤、無機微粒子、マイナスイオン発生剤等を1種又は2種以上を添加してもよい。
【0031】
表面層において、かかるストレッチ糸条単独で織物組織が構成されてもよいし、ストレッチ糸条が経糸(緯糸)に配され、かつ公知のポリエステルやポリアミドなどの繊維形成性ポリマーからなるマルチフィラメントや仮撚捲縮加工糸などの他糸条が緯糸(経糸)に配されていてもよい。その際、経糸または緯糸は全量ストレッチ糸条であることが好ましいが、本発明の主目的のひとつである立体織物のストレッチ性が損なわれない範囲であれば、経糸または緯糸に少量の他糸条がストレッチ糸条とともに配されてもよい。
【0032】
かかる表面層の織物組織としては特に限定されず、平、綾等公知の織組織でよい。なかでも、製造の容易性の点で平組織が好ましく例示される。
【0033】
次に、裏面層も織物組織を有し、かつ前記のように経糸または緯糸として少なくとも結接層の屈曲が連続する方向にはストレッチ糸条が配される。
【0034】
裏面層に配されるストレッチ糸条は、表面層と同様に前記のものが使用される。特に、裏面層に配するストレッチ糸条と、表面層に配するストレッチ糸条とを同一種類とすることが立体織物の製造が容易となるため好ましい。
【0035】
裏面層の織物組織としては特に限定されず、平、綾等公知の織組織でよい。なかでも、製造の容易性の点で平組織が好ましく例示される。
【0036】
前記の表面層と裏面層とを結接する結接層は、波状に屈曲しかつ織物組織を有する。かかる結接層を構成する繊維については特に限定されないが、例えば、結接層を緯糸方向に屈曲(蛇行)させる場合は、結接層を構成する経糸を、表面層を構成する経糸や裏面層を構成する経糸と同一であることが、製造の容易性の点で好ましい。他方、結接層を経糸方向に屈曲(蛇行)させる場合は、結接層を構成する緯糸を、表面層を構成する緯糸や裏面層を構成する緯糸と同一であることが、製造の容易性の点で好ましい。
【0037】
前記の表面層、裏面層、結接層を構成する繊維の繊維形態や繊度は用途に応じて適宜選定される。例えば、結接層を構成する経糸及び緯糸がマルチフィラメントであると、ダンボール状立体織物全体としての柔かさが付加される。また、結接層を経糸方向に屈曲(蛇行)させる場合は結接層を構成する経糸に、結接層を緯糸方向に蛇行させる場合は結接層を構成する緯糸に、単糸繊度5dtex以上の太繊度の糸が配されていると、ダンボール状立体織物全体としての厚みや反撥性が付加される。
【0038】
結接層の織物組織としては特に限定されず、平、綾等公知の織組織でよい。なかでも、製造の容易性の点で平組織が好ましく例示される。
【0039】
次に、本発明のダンボール状立体織物の製造方法について説明する。
本発明のダンボール状立体織物を得るためには、まず、表面層を形成する経糸と裏面層を形成する経糸に熱収縮率11%以上(好ましくは13〜80%)のストレッチ糸条を配し、かつ結接層を形成する経糸に熱収縮率10%以下(好ましくは2〜8%)の糸条を配するか、または、表面層を形成する緯糸と裏面層を形成する緯糸に熱収縮率11%以上(好ましくは13〜80%)のストレッチ糸条を配し、かつ結接層を形成する緯糸に熱収縮率10%以下(好ましくは2〜8%)の糸条を配することにより、織物組織を有する表面層と、織物組織を有する裏面層と、表面層と裏面層とを連結しかつ織物組織を有する結接層で構成される3重織物を織成する。
【0040】
その際、表面層と結接層とを連結する連結点の間隔(裏面層と結接層とを連結する連結点の間隔)が、後記の熱処理後、波状に屈曲した結接層において隣り合う山部の間隔(隣り合う谷部の間隔)が2〜10mm(より好ましくは2〜7mm)となるように選定することが好ましい。
【0041】
ここで、熱収縮率11%以上(好ましくは13〜80%)のストレッチ糸条は、例えば前記のポリエーテルエステルブロック共重合体を用いて公知の紡糸方法で紡糸することにより容易に得られる。
【0042】
他方、熱収縮率10%以下の糸条は、例えば公知のポリエチレンテレフタレートを公知の紡糸・延伸方法で製造する際、温度条件や延伸条件を適宜選定することにより容易に得られる。
【0043】
次いで、該3重織物に80℃以上(好ましくは90〜98℃)の温度で1〜60分間の湿熱処理及び/又は140〜200℃(好ましくは150℃〜180℃)の温度で0.1〜20分間の乾熱処理を施すことにより、表面層の経糸(緯糸)及び/または裏面層の経糸(緯糸)に配された高熱収縮率を有するストレッチ糸条が、結接層を構成する経糸(緯糸)よりも大きく収縮する。その結果、表面層及び/または裏面層を構成する経糸(緯糸)の糸長が結接層を構成する経糸(緯糸)よりも短くなり、結接層が経糸方向(緯糸方向)に波状に屈曲することにより、本発明のダンボール状立体織物が得られる。その際、表面層(裏面層)を構成する経糸(緯糸)と結接層を構成する経糸(緯糸)との糸長差が10%以上(好ましくは20%以上)であることが好ましい。なお、前記の湿熱処理および/または乾熱処理は繰り返し行ってもよい。
【0044】
かかるダンボール状立体織物には、前記熱処理の前および/または後にアルカリ減量加工や常法の染色仕上げ加工が施されてもよい。さらには、常法の吸水加工、撥水加工、起毛加工、さらには、紫外線遮蔽あるいは制電剤、抗菌剤、消臭剤、防虫剤、蓄光剤、再帰反射剤、マイナスイオン発生剤等の機能を付与する各種加工を付加適用してもよい。
【0045】
かくして得られたダンボール状立体織物において、表面層と裏面層には、結接層が屈曲(蛇行の進行方向)する方向にストレッチ糸条が配されている。そのため、結接層が屈曲(蛇行の進行方向)する方向に立体織物が伸長されると、表面層と裏面層では該ストレッチ糸条が伸長され、結接層では屈曲構造が伸長されて平坦になる。そして除荷されると、表面層と裏面層に配されたストレッチ糸条の弾性回復作用により、ダンボール状立体織物は元の寸法に回復する。かかる作用により、本発明のダンボール状立体織物は優れたストレッチ性を有することになる。その際、該ストレッチ性の目安として経方向または緯方向のストレッチ度が10%以上(より好ましくは20%以上)であることが好ましい。
【0046】
さらに、本発明のダンボール状立体織物において、結接層は波状に屈曲しており、かつ織物組織を有しているため、潰れにくく優れたクッション性も得られる。
【0047】
本発明のダンボール状立体織物は、そのクッション性とストレッチ性から多用途に使用することができる。例えば、衣服、スポーツウエアーの全体またはひざ・ひじなどの一部への使用、防寒着、介護医療用衣服、サポーター、ギプス、床ずれ防止マット、靴の中敷き・側地、床マット、ベッドマット、レジャーシート、住宅の壁材、カーテン、カーシート、自動車の内装材、椅子のクッション材・表皮、梱包材、鞄、バッグなどである。
【0048】
【実施例】
次に本発明の実施例及び比較例を詳述するが、本発明はこれらによって限定されるものではない。なお、実施例中の各測定項目は下記の方法で測定した。
<切断伸度(%)>JIS−L−1013に規定されるフィラメント糸の伸び率(%)を測定した。
<織物のストレッチ度(%)>JIS−L−1096に規定される伸縮織物の伸縮性の測定B法で測定した。
<熱水収縮率>周長1.125mの検尺機を用い、試料を10回転サンプリングしてかせを作り、そのかせをスケール板の吊るし釘にかけた後、下部にかせの総繊度の1/30の荷重を吊るし、処理前のかせの長さL1を読む。次に荷重を外し、かせを木綿袋に入れて沸騰水に30分浸ける。その後かせを取り出し、ろ紙で水分を切って24時間風乾した後、再びスケール板の吊るし釘に掛け、下部に上記と同じ荷重を吊るし処理後のかせの長さL2を読み取る。熱水収縮率(BWS)は下記の式により算出した。
BWS(%)=(L1−L2)/L1×100
<捲縮率>周長1.125mの検尺機を用いて総繊度3333dtexのかせを作り、そのかせをスケール板の吊るし釘にかけ下部に6gの初荷重と600gの動荷重を吊るし、かせの長さL0を読み取った後、速やかに動荷重を外すとともにスケール板より外し、沸騰水に30分浸けて、捲縮発現処理を行う。その後かせを取り出し、ろ紙で水分を切って24時間風乾した後、再びスケール板に吊るし、動荷重を掛けて1分後のかせの長さL1を読み取り、次いで、速やかに動荷重を外し1分後のかせの長さL2を読み取る。
捲縮率(%)=(L1−L2)/L0×100
【0049】
[実施例1]
公知のポリエーテルエステル系弾性繊維44dtex/1fil(切断伸度650%)に公知のポリエステルマルチフィラメント仮撚加工糸50dtex/144filを1000T/mカバリングすることにより、ストレッチ糸条(熱水収縮率16%)を得た。
【0050】
次いで、該ストレッチ糸条を表面層の経糸及び裏面層の経糸に用い、結接層の織物組織を構成する経糸として常法により得られた公知のポリエチレンテレフタレートマルチフィラメント66dtex/4fil(熱水収縮率7%)を用い、さらに表面層、裏面層及び結接層の織物組織を構成する緯糸として公知のポリエチレンテレフタレート仮撚加工糸84dtex/72fil(単糸繊度1.17dtex、捲縮率17%)を用いて、熱処理後の結接点間隔d(経糸方向)が5mmとなるように、かつ裏面層と結接層との結接点が、表面層と結接層との隣り合う結接点間の中間に位置するよう、織物組織を設定して平三重織物の生機を得た。
【0051】
該生機に95℃3分間の湿熱処理を施し、次いで(株)ヒラノテクシード製テンターで170℃1分間の乾熱処理を施した後、(株)日阪製作所製液流染色機を用いて分散染料で130℃45分間染色後、(株)ヒラノテクシード製テンターで160℃1分間の乾熱処理を行うことにより、厚み1.9mmのダンボール状立体織物を得た。
【0052】
該ダンボール状立体織物において、表面層と裏面層は平坦な面であり、結接層は緩やかなカーブで波状に屈曲していた。さらに、該結接層において、図1に模式的に示すように隣り合う山部の中間に谷部が位置し、かつ隣り合う山部の間隔dが5mm、隣り合う谷部の間隔が5mmであった。
【0053】
かかるダンボール状立体織物において、クッション性が良好であり、ストレッチ性(ストレッチ度は経方向57%、緯方向6%)も優れたものであった。
【0054】
[比較例1]
モル比が93/7のテレフタル酸/イソフタル酸とエチレングリコールとからなる共重合ポリエステルを常法により、紡糸・延伸した共重合ポリエステルマルチフィラメント33dtex/12fil(熱水収縮率20%)とポリエチレンテレフタレートマルチフィラメント33dtex/72fil(単糸繊度0.46dtex、熱水収縮率3%)とを引き揃えて公知のインターレースノズルを用いて、糸速度600m/minで混繊することにより、インターレース混繊糸を得た。
【0055】
次いで、該インターレース混繊糸表面層の経糸及び裏面層の経糸に用いた以外は実施例1と同様にしてダンボール状立体織物を得た。
【0056】
該ダンボール状立体織物において、表面層と裏面層は平坦な面であり、結接層は緩やかなカーブで波状に屈曲していた。さらに、該結接層において、図1に模式的に示すように隣り合う山部の中間に谷部が位置し、かつ隣り合う山部の間隔dが5mm、隣り合う谷部の間隔が5mmであった。
【0057】
かかるダンボール状立体織物において、クッション性は良好であったが、ストレッチ性(ストレッチ度は経方向4%、緯方向4%)は不十分であった。
【0058】
【発明の効果】
本発明によれば、クッション性を損なうことなくストレッチ性を有するダンボール状立体織物及びその製造方法が提供される。
【図面の簡単な説明】
【図1】本発明に係る表面層、裏面層、及び波状に屈曲した結接層を模式的に例示したものである。
【符号の説明】
1 表面層
2 裏面層
3 結接層[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention is a three-dimensional fabric in which the surface layer and the back surface layer are connected to each other by the binding layer without contacting each other, and the surface layer, the back surface layer, and the binding layer each have a fabric structure, and have stretchability. And a method for producing the same.
[0002]
[Prior art]
BACKGROUND ART Conventionally, a fibrous structure having a structure of a paper cardboard material has been known. For example, a multi-dimensional knitted fabric in which the surface layer and the back surface layer are connected by a binding yarn (for example, see
[0003]
In such a multi-dimensional knitted fabric, the binding yarn has no woven or knitted structure and merely connects the front surface layer and the back surface layer, and thus has a problem that the rigidity is insufficient and the material is easily crushed in the thickness direction.
[0004]
In view of such a problem, the present inventors have previously proposed a cushioning woven fabric in which a front layer and a back layer are connected by an elastic portion having a woven structure (Japanese Patent Application No. 2002-349630). Since the structure of the cushioning fabric is substantially the same as the structure of the cardboard material made of paper, it is excellent in cushioning properties.
[0005]
However, depending on the application, it is desired to have a stretch property, and a proposal for a cardboard-shaped three-dimensional fabric having a stretch property without impairing the cushion property has been desired.
[0006]
[Patent Document 1]
JP-A-7-316959 [Patent Document 2]
Japanese Patent Application Laid-Open No. 11-36164
[Problems to be solved by the invention]
The present invention has been made in order to solve the problems of the prior art, and an object of the present invention is to provide a cardboard-shaped three-dimensional fabric having stretchability without impairing cushioning properties and a method for producing the same. .
[0008]
[Means for Solving the Problems]
The inventor of the present invention has made intensive studies to achieve the above object, and has a surface layer having a woven structure, a back layer having a woven structure, and a binding layer having a wavy and woven structure. In the corrugated cardboard-shaped three-dimensional fabric, stretch yarns as warp or weft constituting the fabric structure are arranged on the front surface layer and the back surface layer in a direction in which the bending of the binding layer is continuous (the traveling direction of meandering), so that a desired pattern is obtained. It has been found that a corrugated three-dimensional woven fabric can be obtained. The present invention has been completed by further intensive studies.
[0009]
Thus, according to the present invention, `` a corrugated cardboard-shaped three-dimensional fabric composed of a surface layer having a woven structure, a back layer having a woven structure, and a binding layer having a woven structure and having a wavy shape, A stretchable corrugated cardboard-shaped woven fabric characterized in that stretch yarns as warps or wefts constituting a woven fabric are arranged in the surface layer and the back surface layer in a direction in which the bending of the binding layer is continuous. " Is provided.
[0010]
In this case, as the stretch yarn, an elastic yarn having a breaking elongation of 70% or more or a composite yarn containing the elastic yarn is preferable.
[0011]
In the corrugated cardboard-shaped three-dimensional woven fabric of the present invention, the valley is located in the middle of the adjacent peaks, and the interval d between the adjacent peaks is in the range of 2 to 10 mm. A stable cushioning property without sag is obtained, which is preferable.
[0012]
Furthermore, in the corrugated cardboard three-dimensional fabric of the present invention, it is preferable that the degree of stretch in the warp or weft direction is 10% or more as a measure of stretchability.
[0013]
The corrugated cardboard-shaped three-dimensional woven fabric of the present invention has a stretch yarn having a heat shrinkage of 11% or more disposed on the warp forming the surface layer and the warp forming the back layer, and has a heat shrinkage of 10% on the warp forming the binding layer. % Or less, or a stretch yarn having a heat shrinkage of 11% or more is arranged on the weft forming the front layer and the weft forming the back layer, and heat is applied on the weft forming the binding layer. By arranging a yarn having a shrinkage factor of 10% or less, a surface layer having a woven structure, a back layer having a woven structure, and a binding layer connecting the surface layer and the back surface layer and having a woven structure are formed. After weaving the triple woven fabric, the triple woven fabric is subjected to a wet heat treatment at a temperature of 80 ° C. or more for 1 to 60 minutes and / or a dry heat treatment at a temperature of 140 to 200 ° C. for 0.1 to 20 minutes. Having a stretch characterized by bending the binding layer in a wavy manner Obtained by the production method of Nboru shaped solid fabric.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail.
The cardboard-shaped three-dimensional woven fabric of the present invention, as schematically shown in FIG. 1 in a cross section in the thickness direction, has a surface layer having a woven structure, a back surface layer having a woven structure, and a binding layer having a woven structure having a wavy bend. It is composed of a contact layer.
[0015]
At that time, the cross-sectional shape schematically shown in FIG. 1 is continuous at the same phase in the warp direction or the weft direction. That is, if the direction in which the binding layer is bent and continuous (the meandering traveling direction) is the warp direction, the peaks and valleys of the binding layer continue in the same phase in the weft direction, and conversely, the binding layer is If the direction that is bent and continuous is the weft direction, the peaks and valleys of the binding layer continue in the warp direction with the same phase.
[0016]
Here, the surface layer and the bonding layer are bonded at the peak of the bonding layer, and on the other hand, the rear surface layer and the bonding layer are bonded at the valley of the bonding layer. In such a binding layer, the traveling direction of the bending may be the warp direction or the weft direction as described above.
[0017]
When the binding layer is bent and continuous in the warp direction, stretch yarns are arranged at least on the warp forming the surface layer and the warp forming the back layer. On the other hand, when the binding layer is bent and continuous in the weft direction, stretch yarns are arranged at least on the weft forming the surface layer and the weft forming the back layer.
[0018]
The above-mentioned surface layer and back surface layer may be flat or may have irregularities. In addition, the binding layer may be meandering by bending in a gentle curve and wavy, or may be bent linearly zigzag.
[0019]
At that time, in the connection layer bent in a wave shape, the valley is located in the middle of the adjacent peaks, and the interval d between the adjacent peaks is in the range of 2 to 10 mm (more preferably, 3 to 7 mm). It is preferable because a stable cushioning property that is hard to set is obtained.
[0020]
In the corrugated cardboard-shaped three-dimensional fabric of the present invention, the thickness is not particularly limited and is appropriately selected depending on the use, but is preferably in the range of 1 to 10 mm (more preferably 1.5 to 7 mm). If the thickness is smaller than 1 mm, sufficient cushioning property may not be obtained. On the other hand, if the thickness is larger than 10 mm, it is likely to be sagged and sufficient rebound may not be obtained.
[0021]
Next, each layer constituting the corrugated cardboard three-dimensional fabric of the present invention will be described.
First, the surface layer has a woven structure, and as described above, the stretch yarn is arranged as a warp or a weft in a direction in which at least the binding layer is continuously bent.
[0022]
Here, the stretch yarn referred to in the present invention is a known elastic yarn, polytrimethylene terephthalate yarn, or a composite yarn containing these yarns, and does not include false twisted crimped yarn. Polytrimethylene terephthalate yarn is known from polytrimethylene terephthalate obtained by polycondensing terephthalic acid or a lower alkyl ester of terephthalic acid represented by dimethyl terephthalate with trimethylene glycol (1,3-propanediol). By spinning according to the spinning method described above.
[0023]
As the stretch yarn, an elastic yarn having a breaking elongation of 70% or more (more preferably 110% or more and 800% or less) or a composite yarn containing the elastic yarn is particularly suitable.
[0024]
Examples of such elastic yarns include polyurethane elastic yarns and polyetherester elastic yarns. In particular, an elastic yarn made of a polyetherester block copolymer is preferably exemplified because of its excellent wet heat resistance, alkali resistance, and heat setting property.
[0025]
Here, the polyetherester block copolymer means a copolymer having an aromatic polyester unit as a hard segment and a poly (alkylene oxide) glycol unit as a soft segment. As the aromatic polyester, an acid component of an acid component is used. 80% by mole or more, preferably 90% by mole or more of one kind of acid component selected from terephthalic acid, 2,6-naphthalenedicarboxylic acid or 4,4'-diphenyldicarboxylic acid, and 80% by mole of glycol component As described above, preferably 90% by mole or more of a polyester composed of one kind of low molecular weight glycol selected from 1,4-butanediol, ethylene glycol and 1,3-propanediol is used.
[0026]
Examples of the poly (alkylene oxide) glycol include polyethylene glycol, poly (propylene oxide) glycol, poly (tetramethylene oxide) glycol, and the like. Preferably, a homopolymer of poly (tetramethylene oxide) glycol or the above-mentioned homopolymer is used. A random copolymer or a block copolymer in which two or more of the repeating units constituting the coalesced are copolymerized in random or block form, or a mixed polymer in which two or more of the homopolymers or copolymers are further mixed Is used.
[0027]
The molecular weight of the poly (alkylene oxide) glycol used here is preferably 400 to 4000, particularly preferably 600 to 3500. When the average molecular weight is less than 400, the resulting polyetherester block copolymer tends to have poor elasticity due to reduced blockability. When the average molecular weight exceeds 4,000, the resulting polymer undergoes phase separation to form a block copolymer. It is difficult to become a polymer and tends to be inferior in elastic performance.
[0028]
Such a polyetherester block copolymer can be produced according to a usual method for producing a copolymerized polyester. Specifically, the acid component and / or an alkyl ester thereof and a low molecular weight glycol and a poly (alkylene oxide) glycol are put into a reactor, and a transesterification reaction or an esterification reaction is performed in the presence or absence of a catalyst. Further, it is a method in which a polycondensation reaction is carried out under a high vacuum to increase the degree of polymerization to a desired degree.
[0029]
When the stretch yarn is a composite yarn including the elastic yarn or the polytrimethylene terephthalate yarn, air processing such as taslan processing or interlace processing, and composite false twist processing using the elastic yarn and a known polyester filament. A composite yarn obtained by twisting, covering, or the like is suitable in terms of excellent texture and handleability.
[0030]
If necessary, matting agents, fine pore-forming agents, cationic dyeing agents, coloring inhibitors, heat stabilizers, heat stabilizers, etc. may be added to the polymer forming the stretch yarn as long as the object of the present invention is not impaired. One or more of a flame retardant, a fluorescent whitening agent, a coloring agent, an antistatic agent, a moisture absorbent, an antibacterial agent, inorganic fine particles, a negative ion generator and the like may be added.
[0031]
In the surface layer, the stretch yarn alone may constitute a woven fabric structure, or the stretch yarn may be arranged on a warp (weft), and may be a multifilament or a temporary filament made of a known fiber-forming polymer such as polyester or polyamide. Other yarns such as twisted crimped yarns may be arranged on the weft (warp). At that time, the warp or the weft is preferably a stretch yarn in the whole amount, but as long as the stretchability of the three-dimensional woven fabric, which is one of the main objects of the present invention, is not impaired, a small amount of the other yarn in the warp or the weft yarn. May be arranged with the stretch yarn.
[0032]
The woven structure of the surface layer is not particularly limited, and may be a known woven structure such as flat or twill. Among them, a flat structure is preferably exemplified in terms of ease of production.
[0033]
Next, the back layer also has a woven structure, and a stretch yarn is arranged as a warp or a weft in the direction in which at least the binding layer is continuously bent as described above.
[0034]
As the stretch yarns disposed on the back surface layer, those described above are used as in the case of the surface layer. In particular, it is preferable that the stretch yarns arranged on the back surface layer and the stretch yarns arranged on the surface layer be of the same type, since the production of the three-dimensional fabric is facilitated.
[0035]
The woven structure of the back layer is not particularly limited, and may be a well-known woven structure such as flat or twill. Among them, a flat structure is preferably exemplified in terms of ease of production.
[0036]
The joining layer that joins the front surface layer and the back layer is bent in a wave shape and has a woven structure. The fibers constituting the binding layer are not particularly limited. For example, when the binding layer is bent (meandered) in the weft direction, the warp constituting the binding layer is replaced with the warp constituting the surface layer or the back layer. Is preferably the same as the warp constituting the above from the viewpoint of ease of production. On the other hand, in the case of bending (meandering) the binding layer in the warp direction, it is easy to manufacture that the weft constituting the binding layer is the same as the weft constituting the surface layer and the weft constituting the back layer. It is preferred in terms of.
[0037]
The fiber form and fineness of the fibers constituting the surface layer, the back layer, and the binding layer are appropriately selected depending on the application. For example, if the warp and the weft constituting the binding layer are multifilaments, the softness of the cardboard-shaped three-dimensional fabric as a whole is added. When the binding layer is bent (meandered) in the warp direction, the warp constituting the binding layer is provided. When the binding layer is provided in the weft direction, the weft constituting the binding layer is provided with a single yarn fineness of 5 dtex or more. When the yarn having the large fineness is arranged, the thickness and the resilience of the corrugated cardboard-shaped three-dimensional fabric as a whole are added.
[0038]
The woven structure of the binding layer is not particularly limited, and may be a known woven structure such as flat or twill. Among them, a flat structure is preferably exemplified in terms of ease of production.
[0039]
Next, a method for producing a three-dimensional cardboard woven fabric of the present invention will be described.
In order to obtain the cardboard-shaped three-dimensional woven fabric of the present invention, first, a stretch yarn having a heat shrinkage of 11% or more (preferably 13 to 80%) is arranged on the warp forming the front layer and the warp forming the back layer. And, a yarn having a heat shrinkage of 10% or less (preferably 2 to 8%) is disposed on the warp forming the binding layer, or the heat shrinkage is performed on the weft forming the surface layer and the weft forming the back surface layer. A stretch yarn having a rate of 11% or more (preferably 13 to 80%) is arranged, and a yarn having a heat shrinkage of 10% or less (preferably 2 to 8%) is arranged on the weft forming the binding layer. Thus, a triple woven fabric composed of a surface layer having a woven structure, a back surface layer having a woven structure, and a binding layer connecting the surface layer and the back surface layer and having a woven structure is woven.
[0040]
At that time, the distance between the connection points connecting the surface layer and the bonding layer (the distance between the connection points connecting the rear surface layer and the bonding layer) is adjacent to each other in the wavy bent bonding layer after the heat treatment described below. It is preferable to select the distance between the peaks (the distance between adjacent valleys) to be 2 to 10 mm (more preferably, 2 to 7 mm).
[0041]
Here, a stretch yarn having a heat shrinkage of 11% or more (preferably 13 to 80%) can be easily obtained by, for example, spinning the above-mentioned polyetherester block copolymer by a known spinning method.
[0042]
On the other hand, a yarn having a heat shrinkage of 10% or less can be easily obtained by appropriately selecting temperature conditions and stretching conditions when, for example, a known polyethylene terephthalate is produced by a known spinning and stretching method.
[0043]
Then, the triple woven fabric is subjected to wet heat treatment at a temperature of 80 ° C. or more (preferably 90 to 98 ° C.) for 1 to 60 minutes and / or 0.1 to 140 ° C. to 200 ° C. (preferably 150 ° C. to 180 ° C.). By performing the dry heat treatment for up to 20 minutes, the stretch yarns having a high heat shrinkage ratio arranged on the warp (weft) of the surface layer and / or the warp (weft) of the back surface layer constitute the binding yarn ( (Weft). As a result, the yarn length of the warp (weft) constituting the surface layer and / or the back surface layer is shorter than the warp (weft) constituting the binding layer, and the binding layer is bent in a wavy direction in the warp direction (weft direction). By doing so, the cardboard-shaped three-dimensional fabric of the present invention is obtained. At that time, it is preferable that the difference in yarn length between the warp (weft) constituting the surface layer (backside layer) and the warp (weft) constituting the binding layer is 10% or more (preferably 20% or more). Note that the above-mentioned wet heat treatment and / or dry heat treatment may be repeatedly performed.
[0044]
Before and / or after the heat treatment, the corrugated cardboard-shaped three-dimensional fabric may be subjected to an alkali weight reduction process or a conventional dyeing finish process. In addition, functions such as ordinary water absorption, water repellency, and brushing, as well as ultraviolet shielding or antistatic agents, antibacterial agents, deodorants, insect repellents, phosphorescent agents, retroreflective agents, and negative ion generators May be additionally applied.
[0045]
In the corrugated cardboard-shaped three-dimensional woven fabric thus obtained, stretch yarns are arranged on the front surface layer and the back surface layer in a direction in which the binding layer bends (the traveling direction of meandering). Therefore, when the three-dimensional woven fabric is stretched in a direction in which the binding layer is bent (the traveling direction of the meandering), the stretch yarn is stretched in the front layer and the back layer, and the bent structure is stretched in the binding layer to be flat. Become. Then, when unloaded, the cardboard-shaped three-dimensional fabric is restored to its original size by the elastic recovery effect of the stretch yarns arranged on the surface layer and the back surface layer. By such an action, the three-dimensional corrugated cardboard fabric of the present invention has excellent stretchability. At that time, it is preferable that the degree of stretching in the warp or weft direction is 10% or more (more preferably 20% or more) as a measure of the stretchability.
[0046]
Furthermore, in the corrugated cardboard three-dimensional fabric of the present invention, the binding layer is bent in a wave shape and has a fabric structure, so that it is hard to be crushed and excellent cushioning properties can be obtained.
[0047]
The corrugated cardboard three-dimensional fabric of the present invention can be used for various purposes because of its cushioning property and stretch property. For example, clothing, use of sportswear on the whole or part of knees, elbows, etc., winter clothes, nursing care clothes, supporters, casts, bedsore prevention mats, insoles / sides, floor mats, bed mats, leisure Seats, house wall materials, curtains, car seats, car interior materials, chair cushions / skins, packing materials, bags, bags, and the like.
[0048]
【Example】
Next, Examples and Comparative Examples of the present invention will be described in detail, but the present invention is not limited by these. In addition, each measurement item in an Example was measured by the following method.
<Cutting elongation (%)> The elongation (%) of the filament yarn specified in JIS-L-1013 was measured.
<Stretch Degree of Fabric (%)> The stretchability of stretchable fabric specified in JIS-L-1096 was measured by the B method.
<Hot water shrinkage> A skein was made by sampling a sample 10 times using a measuring machine having a circumference of 1.125 m, and the skein was hung on a hanging nail of a scale plate. Hang a load of 30 and read the skein length L1 before processing. Then remove the load and put the skein in a cotton bag and soak in boiling water for 30 minutes. Thereafter, the skein is taken out, dried with a filter paper and air-dried for 24 hours, again hung on a hanging nail of a scale plate, and the same load is hung below the scale plate, and the skein length L2 after processing is read. The hot water shrinkage (BWS) was calculated by the following equation.
BWS (%) = (L1−L2) / L1 × 100
<Crimping ratio> A skein having a total fineness of 3333 dtex was made using a measuring machine having a circumference of 1.125 m, and the skein was hung on a hanging nail of a scale plate, and an initial load of 6 g and a dynamic load of 600 g were hung below the skein. After reading the length L0, the dynamic load is immediately removed and the scale is removed from the scale plate, and immersed in boiling water for 30 minutes to perform a crimp development process. Thereafter, the skein is taken out, dried with a filter paper, air-dried for 24 hours, suspended again on the scale plate, and subjected to a dynamic load, read the skein length L1 one minute later, and then immediately removed the dynamic load for one minute. Read the length of the skein L2.
Crimp rate (%) = (L1−L2) / L0 × 100
[0049]
[Example 1]
A stretch yarn (hot water shrinkage of 16%) is formed by covering a known polyester multifilament false twisted yarn of 50 dtex / 144fill with 1000 T / m on a known polyetherester-based elastic fiber of 44 dtex / 1fil (cutting elongation of 650%). ) Got.
[0050]
Next, the stretch yarn is used for the warp of the surface layer and the warp of the back layer, and a known polyethylene terephthalate multifilament 66 dtex / 4fil (hot water shrinkage) obtained by a conventional method as a warp constituting a woven fabric structure of the binding layer. 7%), and a known polyethylene terephthalate false twisted yarn 84dtex / 72fil (single yarn fineness 1.17dtex, crimp rate 17%) as a weft constituting the fabric structure of the surface layer, the back surface layer and the binding layer. In this case, the distance d (warp direction) after the heat treatment is 5 mm, and the bonding point between the back layer and the bonding layer is located between the adjacent bonding points between the surface layer and the bonding layer. The woven fabric was set so as to be positioned, and a green fabric of a plain triple woven fabric was obtained.
[0051]
The greige was subjected to a wet heat treatment at 95 ° C. for 3 minutes, followed by a dry heat treatment at 170 ° C. for 1 minute using a tenter manufactured by Hirano Tecseed Co., Ltd., followed by disperse dyeing using a liquid flow dyeing machine manufactured by Hisaka Seisakusho Co., Ltd. After dyeing at 130 ° C. for 45 minutes, a dry heat treatment at 160 ° C. for 1 minute was performed with a tenter manufactured by Hirano Tecseed Co., Ltd. to obtain a 1.9 mm thick corrugated cardboard fabric.
[0052]
In the corrugated cardboard-shaped three-dimensional fabric, the front surface layer and the back surface layer were flat surfaces, and the binding layer was bent in a gentle curve in a wavy manner. Further, in the binding layer, as schematically shown in FIG. 1, a valley is located in the middle of the adjacent peaks, and the interval d between the adjacent peaks is 5 mm, and the interval between the adjacent valleys is 5 mm. there were.
[0053]
In the corrugated cardboard-shaped three-dimensional woven fabric, the cushioning property was good, and the stretchability (the stretching degree was 57% in the warp direction and 6% in the weft direction) was also excellent.
[0054]
[Comparative Example 1]
A copolyester composed of terephthalic acid / isophthalic acid having a molar ratio of 93/7 and ethylene glycol is spun and drawn by a conventional method to obtain a copolyester multifilament 33dtex / 12fil (shrinkage ratio of hot water 20%) and polyethylene terephthalate multifilament. A 33dtex / 72fil filament (0.46 dtex single yarn fineness, 3% hot water shrinkage ratio) is aligned and mixed at a yarn speed of 600 m / min using a known interlace nozzle to obtain an interlaced mixed yarn. Was.
[0055]
Next, a corrugated cardboard-shaped three-dimensional fabric was obtained in the same manner as in Example 1 except that the interlaced mixed fiber was used for the warp of the surface layer and the warp of the back layer.
[0056]
In the corrugated cardboard-shaped three-dimensional fabric, the front surface layer and the back surface layer were flat surfaces, and the binding layer was bent in a gentle curve in a wavy manner. Further, in the binding layer, as schematically shown in FIG. 1, a valley is located in the middle of the adjacent peaks, and the interval d between the adjacent peaks is 5 mm, and the interval between the adjacent valleys is 5 mm. there were.
[0057]
In the corrugated cardboard-shaped three-dimensional fabric, the cushioning property was good, but the stretchability (stretch degree was 4% in the warp direction and 4% in the weft direction) was insufficient.
[0058]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the cardboard-shaped three-dimensional fabric which has a stretch property without impairing a cushion property, and its manufacturing method are provided.
[Brief description of the drawings]
FIG. 1 schematically illustrates a front surface layer, a back surface layer, and a wavy bent binding layer according to the present invention.
[Explanation of symbols]
Claims (5)
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
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JP2003018512A JP2004232095A (en) | 2003-01-28 | 2003-01-28 | Corrugated board-like three-dimensional woven fabric having stretchability and method for producing the same |
TW092133599A TWI276715B (en) | 2002-12-02 | 2003-11-28 | Three-dimensional fabric and method for producing the same |
KR1020057003935A KR20050084812A (en) | 2002-12-02 | 2003-12-01 | Three-dimensional fabric and method for production thereof |
EP03812364A EP1568808A4 (en) | 2002-12-02 | 2003-12-01 | Three-dimensional fabric and method for production thereof |
PCT/JP2003/015345 WO2004050972A1 (en) | 2002-12-02 | 2003-12-01 | Three-dimensional fabric and method for production thereof |
CA002493796A CA2493796A1 (en) | 2002-12-02 | 2003-12-01 | Three-dimensional woven fabric and process for its production |
US10/521,169 US20060060257A1 (en) | 2002-12-02 | 2003-12-01 | Three-dimensional fabric and method for production thereof |
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JP2003018512A JP2004232095A (en) | 2003-01-28 | 2003-01-28 | Corrugated board-like three-dimensional woven fabric having stretchability and method for producing the same |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2019139177A1 (en) * | 2019-03-01 | 2019-07-18 | カイハラ産業株式会社 | Stretchable fabric, and manufacturing method and manufacturing device for same |
CN110284237A (en) * | 2019-07-07 | 2019-09-27 | 徐州荣盛达纤维制品科技有限公司 | A kind of nothing is threaded line cold protective clothing fabric and preparation method thereof |
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2003
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2019139177A1 (en) * | 2019-03-01 | 2019-07-18 | カイハラ産業株式会社 | Stretchable fabric, and manufacturing method and manufacturing device for same |
JPWO2019139177A1 (en) * | 2019-03-01 | 2020-04-16 | カイハラ産業株式会社 | Stretchable fabric, its manufacturing method and manufacturing apparatus |
US12037720B2 (en) | 2019-03-01 | 2024-07-16 | Kaihara Co., Ltd. | Stretchable fabric, and manufacturing method and manufacturing device for same |
CN110284237A (en) * | 2019-07-07 | 2019-09-27 | 徐州荣盛达纤维制品科技有限公司 | A kind of nothing is threaded line cold protective clothing fabric and preparation method thereof |
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