JP2005068605A - Three-dimensional knitted fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a three-dimensional knitted fabric generating little harsh noise by the variation of load on a cushioning material composed of the knitted fabric and having good cushioning property in the case of using the knitted fabric as a cushioning material, especially as a seat having the three-dimensional knitted fabric spread on a frame to form the seat and/or the seat back. <P>SOLUTION: The three-dimensional knitted fabric is composed of front and back knitted fabrics and a connection layer composed of a connecting yarn to connect the knitted fabric layers. The noise level generated by the compression of the three-dimensional knitted fabric is ≤65 dB, the connecting yarn is formed by the blending of a monofilament and a multifilament in knitting, the blended weight ratio of the multifilament is ≥10% but ≤50%, and the single fiber fineness of the multifilament is ≤20 dtex. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a three-dimensional knitted fabric and a three-dimensional knitted fabric for a seat that are preferably used for seats for automobiles, railway vehicles, aircraft, child seats, strollers, wheelchairs, furniture, office work, and the like.

A three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and connecting yarns that connect the two layers of knitted fabrics, utilizing various functions such as cushioning, breathability, heat retention, body pressure dispersibility, etc. It is used for purposes.
These three-dimensional knitted fabrics are imparted with cushioning properties in the thickness direction of the three-dimensional knitted fabric by using monofilaments for the connecting yarns constituting the intermediate layer, utilizing the bending elasticity of the monofilaments. As such a three-dimensional knitted fabric, for example, in Patent Document 1, a three-dimensional knitted fabric (expressed as a three-layer structure three-dimensional fabric), a backing material such as a cloth or a nonwoven fabric, a batting fiber, and a backing fabric are laminated. Further, a cushion material is disclosed in which these are quilted integrally and the outer periphery is sewn with hem.

In many cases, three-dimensional knitted fabrics used for cushioning materials are thick enough to support body pressure on the connecting yarns that make up the three-dimensional knitted fabric in order to improve cushioning when body pressure is applied. That is, a monofilament having a single yarn fineness of 20 dtex or more is often used. For this reason, when a three-dimensional knitted fabric is actually used as a cushion material for a seat, the monofilament of this connecting thread is deformed due to the weight load, and an irritating sound is generated each time the body is moved due to friction between the monofilaments, It was something that caused discomfort.
Japanese Utility Model Publication No. 6-22283

  The present invention solves the above-mentioned problems, and when a three-dimensional knitted fabric is used as a cushioning material, in particular, when a three-dimensional knitted fabric is stretched on a frame and used as a seat that forms a seat and / or a back portion, the cushion An object of the present invention is to provide a three-dimensional knitted fabric with good cushioning properties while reducing the harsh sound that occurs when the load on the material fluctuates.

In order to achieve the above object, the present inventor has intensively studied the compression characteristics of a three-dimensional knitted fabric, the fiber material and fiber form used for the three-dimensional knitted fabric, the tension compression characteristics of the three-dimensional knitted fabric, and the like. It came.
That is, the present invention is as follows.
(1) A three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and a connecting layer comprising connecting yarns connecting the two knitted fabrics, and the sound generation level during compression of the three-dimensional knitted fabric is 65 dB or less. Yes, monofilaments and multifilaments are knitted at the time of knitting to form a connecting yarn, the multifilament weight mixing ratio in the connecting yarn is 10% or more and 50% or less, and the single filament fineness of the multifilament is 20 decitex or less A three-dimensional knitted fabric characterized by that.
(2) At the time of 245N load tension compression deflection using a disk-shaped compression jig with a diameter of 100 mm, a 245N load tension compression deflection amount using a disk-shaped compression jig with a diameter of 100 mm is 15 mm or more and 80 mm or less. The three-dimensional knitted fabric according to (1), wherein the hysteresis loss rate is 70% or less.
(3) The three-dimensional knitted fabric according to (1) or (2), wherein a silicone oil is adhered to the solid knitted fabric in a solid content of 0.05 wt% or more and 5.0 wt% or less.
(4) The three-dimensional knitted fabric according to (1) or (2), wherein fibers having a single yarn fineness of 0.1 dtex or more and 10 dtex or less are attached to the three-dimensional knitted fabric by a flocking process.
(5) The three-dimensional knitted fabric for seats according to any one of (1) to (4).
(6) A hammock-type seat in which the three-dimensional knitted fabric for a seat according to (5) is used as a cushion material for a back portion and / or a seat portion.

  When the three-dimensional knitted fabric of the present invention is used as a cushioning material, it reduces the sound generation level when compressing the three-dimensional knitted fabric, thereby reducing the annoying sound that occurs when the load on the cushioning material changes, such as when sitting. Is done. Furthermore, the three-dimensional knitted fabric of the present invention is excellent in cushioning properties. In particular, a three-dimensional knitted fabric is stretched around the frame to provide excellent cushioning for the seat forming the seat and / or the back.

Hereinafter, the present invention will be described in detail.
When the three-dimensional knitted fabric of the present invention is used as a cushioning material, it is necessary to reduce the noise level and to obtain a comfortable sitting comfort, the sound generation level when compressing the three-dimensional knitted fabric is 65 dB or less, Preferably it is 63 dB or less, More preferably, it is 60 dB or less. When the sound generation level exceeds 65 dB, when a three-dimensional knitted fabric is used as a cushion material for a seat, for example, an unpleasant sound is generated each time the body is moved, causing uncomfortable feeling.

  In order to reduce the sound generation level of the three-dimensional knitted fabric of the present invention to 65 dB or less, monofilaments and multifilaments are knitted at the time of knitting to form connected yarns, and the weight mixing ratio of the multifilament connected yarns is 10% to 50%. % Or less, preferably 10% or more and 45% or less, more preferably 10% or more and 40% or less. When the weight mixing ratio in the multifilament connecting yarn is less than 10%, the monofilament of the connecting yarn is deformed by the load of the body weight, and an unpleasant sound due to rubbing of the monofilaments cannot be prevented. When the weight mixing ratio in the multifilament connecting yarn exceeds 50%, the compression elasticity of the monofilament in the connecting yarn is not exhibited, the elasticity and good fit of the connecting layer cannot be obtained, and the sitting comfort is deteriorated.

The single yarn fineness of the multifilament constituting the connecting yarn is 20 dtex or less, preferably 15 dtex or less, more preferably 10 dtex or less. When the single filament fineness of the multifilament exceeds 20 dtex, the bending rigidity at the time of compression of the multifilament is too large, and the effect of preventing annoying sound due to rubbing is not sufficiently exhibited.
In the three-dimensional knitted fabric of the present invention, it is preferable that the silicone oil is adhered to the solid knitted fabric in a solid content of 0.05 wt% or more and 5 wt% or less, more preferably 0.2 wt% or more and 5 wt% or less. If the adhesion amount of the silicone-based oil agent is less than 0.05 wt%, the surface of the fiber material used in the three-dimensional knitted fabric cannot be sufficiently covered, and the effect of reducing the squeak noise may not be sufficiently exhibited. If the adhesion amount exceeds 5 wt%, the surface of the three-dimensional knitted fabric may remain sticky and feel uncomfortable.

  In the three-dimensional knitted fabric of the present invention, fibers having a single yarn fineness of preferably 0.1 dtex or more and 10 dtex or less, more preferably 1.0 or more and 6.0 dtex or less are preferably adhered by flocking. When the single yarn fineness of the adhering fiber is less than 0.1 dtex, the buffering effect of the squeak noise at the time of compression by the flocking process is small, and when it exceeds 10 dtex, the absolute number of single yarns to be attached decreases and the squeak noise is sufficient. May not be able to obtain a sufficient reduction effect. Although the single yarn length is not limited, 0.1 to 5 mm is preferable in consideration of the workability of flocking. By using the fiber (original fiber) containing the pigment for the flocking process, the three-dimensional knitted fabric can be freely colored.

When the three-dimensional knitted fabric of the present invention is used as a cushion material for a hammock-type seat, the 245N load tension compression deflection amount using a disk-shaped compression jig having a diameter of 100 mm is 15 mm or more and 80 mm or less. It is preferable in improving cushioning properties, improving the fit with the human body, and obtaining a comfortable sitting comfort.
The 245N load tension compression deflection amount using a disk-shaped compression jig with a diameter of 100 mm of a three-dimensional knitted fabric is fixed to the frame around the three-dimensional knitted fabric cut into a square, and has a diameter of 100 mm perpendicular to the surface of the three-dimensional knitted fabric. This is the amount of compressive deflection of the surface of the three-dimensional knitted fabric when a load of 245N is applied to the circular flat compression jig, and is greatly influenced by the compression characteristics of the front and back layers and the connecting layer of the three-dimensional knitted fabric. . If the amount of tension and deformation of the three-dimensional knitted fabric is less than 15 mm, there is little sinking when a person sits down, so that it does not fit the human body and the sitting comfort may be lowered. On the other hand, if the tension compression deflection exceeds 80 mm, the sinking when the person is seated increases, the seat surface is wobbled and does not fit the human body, and the seat surface may be easily dented after sitting. is there.

Hammock-type seat cushioning material is a material in which a three-dimensional knitted fabric is in a sail-like state by stretching the periphery or at least two sides of the three-dimensional knitted fabric in a tensioned or slackened state on a seat frame or a chair frame. It forms the seat part and the backrest part of the cushion material for seats. The cushioning property of the three-dimensional knitted fabric is particularly effectively reflected when the three-dimensional knitted fabric is used as a cushion material for a hammock-type seat.
The three-dimensional knitted fabric of the present invention preferably has a hysteresis loss rate of 245N load tension compression deflection using a disk-shaped compression jig having a diameter of 100 mm, preferably 70% or less, more preferably 65% or less, and even more preferably 60% or less. Yes, the closer to 0, the better. When the hysteresis loss rate exceeds 70%, the recoverability is lowered and good cushioning properties may not be obtained.

  In order to reduce the hysteresis loss rate at the time of 245N load tension compression deformation using a disk-shaped compression jig having a diameter of 100 mm of a three-dimensional knitted fabric, the fibers constituting the surface layer and the back layer of the three-dimensional knitted fabric are stretched at 0% or more. An elongation heat treatment method or the like is used. The heat treatment may be performed under the feed in the yarn manufacturing stage such as the raw yarn manufacturing stage, false twisting, fluid injection processing or the like, or may be performed in the knitted fabric stage. In the case where the heat treatment is performed on the knitted fabric, it is preferable to perform the heat treatment at an elongation rate of 5% or more in the width direction.

  The three-dimensional knitted fabric of the present invention is composed of two layers of front and back knitted fabrics and connecting yarns that connect the two knitted fabrics. When knitting a three-dimensional knitted fabric with a double raschel knitting machine, a double circular knitting machine, or a flat knitting machine, the connecting yarns that connect the front and back knitted fabrics are always knitted in a curved state in either direction. When a force is applied to the connecting yarn from the thickness direction, the connecting yarn is further bent from the already bent state, and when the force is removed, the original state is restored. Since the bending and recovery behavior of the connecting yarn that occurs at this time greatly affects the cushioning properties of the solid knitted fabric, it is necessary to use monofilaments and multifilaments with high bending rigidity that are knitted together during knitting. preferable.

In order to give the three-dimensional knitted fabric with a powerful stretch property or compression deflection property and recoverability, it is preferable to use a monofilament for at least one knitted fabric of the front and back layers. It is preferable that the monofilament is a composite yarn such as side-by-side because stretchability and recoverability are further improved.
The fineness of the monofilament used for the front and back knitted fabrics and connecting yarns of the present invention is usually 200 to 1000 dtex, and 250 to 700 from the viewpoint of imparting a soft cushion and more excellent cushioning properties to the three-dimensional knitted fabric. Decitex is preferred, more preferably 300 to 550 decitex. The multifilament used for the front and back knitted fabric and the connecting yarn is composed of two or more single yarns of 20 dtex or less, and the total fineness is preferably 50 to 2000 dtex. The number of filaments constituting the multifilament can be arbitrarily set.

Examples of the monofilament include fibers of any material such as polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, polyethylene terephthalate fiber, polyamide fiber, polypropylene fiber, polyvinyl chloride fiber, and polyester elastomer fiber. Among these, it is preferable to use polytrimethylene terephthalate fiber for at least a part of the connecting yarn because it has a cushioning property with elasticity and durability by repeated compression is improved.
The cross-sectional shape of the monofilament may be round, triangular, L-shaped, T-shaped, Y-shaped, W-shaped, Yaba-shaped, flat-shaped, dog-bone-shaped, etc., multi-leafed, hollow or irregular However, a round cross section is preferable for improving the durability of the cushioning property of the three-dimensional knitted fabric.

  Multifilaments include polyester fibers such as polyethylene terephthalate fibers, polytrimethylene terephthalate fibers and polybutylene terephthalate fibers, synthetic fibers such as polyamide fibers, polyacrylic fibers and polypropylene fibers, and natural fibers such as cotton, hemp and wool. Any fiber such as fiber, recycled fiber such as cupra rayon, viscose rayon, lyocell and the like can be mentioned. Among these, use of polytrimethylene terephthalate fiber is preferable because the amount of compression deflection can be increased when a three-dimensional knitted fabric is used for a cushion material for a hammock type seat, and the stroke feeling and fit feeling are good. Furthermore, polytrimethylene terephthalate fiber has an elongation rate of 0% or more, and is subjected to elongation heat treatment at the stage of raw yarn production, yarn processing, or knitted fabric, in order to reduce the hysteresis loss rate and residual strain during compression deflection. More preferred.

The cross-sectional shape of the single filament constituting the multifilament is round, triangular, L-shaped, T-shaped, Y-shaped, W-shaped, eight-leaf-shaped, flat-shaped, flat-shaped, dog-bone-shaped, etc., multi-leaf, hollow Or an irregular shape. The form of the fiber may be any of unprocessed yarn, spun yarn, twisted yarn, false twisted yarn, fluid injection processed yarn and the like. In order to increase the coverage so that the monofilament of the connecting yarn is not exposed to the surface of the knitted fabric, it is preferable to use a bulky yarn such as a multifilament false twisted yarn or a spun yarn on at least one side of the front and back layers of the three-dimensional knitted fabric . The single filament fineness of the multifilament is preferably 15 dtex or less in order to obtain a soft texture.
When the front and back yarns and the connecting yarn of the three-dimensional knitted fabric are made of 100% polyester fiber, it is possible to recycle the monomer by depolymerization at the time of disposal, and it is possible to prevent generation of harmful gas even if incinerated.

The three-dimensional knitted fabric of the present invention can be knitted by a knitting machine having two rows of needle beds facing each other. As the knitting machine, for example, a double raschel knitting machine, a double circular knitting machine, a flat knitting machine having a V bed, or the like is used. In order to obtain a three-dimensional knitted fabric with good dimensional stability, it is preferable to use a double raschel knitting machine. The gauge of the knitting machine is preferably 9 to 28 gauge.
The front and back knitted fabrics of the three-dimensional knitted fabric can be reduced in weight and air permeability by using a knitted fabric having a plurality of openings such as a quadrangular or hexagonal mesh knitted fabric or a Maggie jet knitted fabric. By making the surface a flat structure or raising the surface, a material having a good touch can be obtained.

The number of the connecting yarns in the area of the solid knitted fabric 6.45 cm ² is N (pieces / 6.45 cm ² ), the decitex of the connecting yarns is T (g / 1 × 10 ⁶ cm), and the specific gravity of the connecting yarns is ρ ₀ ( g / cm ³⁾ and when the total cross-sectional area (N · T / 1 × 10 6 · ρ 0 of connecting yarns that are in the area of the three-dimensional knit fabric 6.45 cm ²⁾ is preferably 0.05～0.25Cm ² More preferably, it is 0.07-0.20 cm < ² >. By setting the total cross-sectional area of the connecting yarn within this range, the three-dimensional knitted fabric has a good cushioning property with a more appropriate rigidity.

The connecting yarn of the three-dimensional knitted fabric may form loop stitches in the front and back knitted fabrics, or may have a structure that is hooked on the front and back knitted fabrics in an inserted structure, but at least two connecting yarns connect the front and back knitted fabrics to each other Inclining in the opposite direction and connecting in a cross shape (X shape) or a truss shape is preferable for improving the shape stability of the three-dimensional knitted fabric.
The thickness and basis weight of the three-dimensional knitted fabric can be arbitrarily set according to the purpose, but the thickness is preferably 3 to 30 mm. If the thickness is less than 3 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 generally 150 to 3000 g / m ² , preferably 200 to 2000 g / m ² .

  The fibers used for the front and back knitted fabric and the connecting yarn of the present invention are preferably colored. Coloring methods include dying uncolored yarn in the form of skein or cheese (dyeing), coloring by mixing pigments, dyes, etc. in the stock solution before spinning (dye solution coloring), dyeing in three-dimensional knitting A printing method or the like is used. When dyed in the form of a three-dimensional knitted fabric, it is difficult to maintain the three-dimensional shape or the workability may be lowered.

  The silicone-based oil applied to the three-dimensional knitted fabric of the present invention may be any of a straight system, a solvent system, and an emulsion system, and is appropriately selected depending on the use and workability. The type of silicone oil is not limited, and dimethylpolysiloxane, alkylaralkyl-modified silicone, polyether-modified silicone, fluorine-modified silicone, amino-modified silicone (terminal reactive type, terminal non-reactive type), and the like are used. Those obtained by adding various surfactants or the like to these silicone oils to increase the feeling of sliding, or those obtained by adding a polymer thickener may be used.

The adhesion amount of the silicone-based oil agent is preferably in the range of 0.05 wt% or more and 5.0 wt% or less with respect to the three-dimensional knitted fabric.
A method for applying a silicone oil will be described by taking an emulsion silicone oil as an example.
First, the three-dimensional knitted fabric is immersed in a diluted solution of an emulsion-based silicone oil. The immersion time is preferably 0.1 to 100 seconds. The solution concentration of the emulsion silicone oil is preferably 0.1 wt% or more and 8 wt% or less in terms of solid content. Subsequently, the mangle pressure is preferably 0.2 to 1 MPa, more preferably 0.3 to 0.6 MPa, and the processing speed of the mangle restrictor is preferably 1 to 100 m / min, more preferably with a mangle restrictor. Squeeze under conditions of 2 to 10 m / min.

Next, using a circulating hot air dryer, the temperature in the dryer is preferably 120 to 200 ° C., more preferably 140 to 190 ° C., and the drying time is preferably 0.1 to 10 minutes, more preferably 0.5 to Dry under conditions of 8 minutes.
As for the finishing method of the three-dimensional knitted fabric, in the case of the three-dimensional knitted fabric using the pre-dyed yarn or the undiluted solution colored yarn, the raw machine can be finished through processes such as scouring and heat setting. When either the connecting yarn or the front and back yarns are uncolored three-dimensional knitted fabric, the raw machine can be finished through processes such as scouring, dyeing and heat setting.
The finished three-dimensional knitted fabric can be used for various applications such as cushioning materials by processing the end by means of fusion, sewing, resin processing, or by forming it into a desired shape by thermoforming or the like.

The measuring method of various physical properties of the three-dimensional knitted fabric is as follows.
(1) Sound generation level when compressing a solid knitted fabric As a volume measuring device, “SOUND LEVEL METER” SL-1350 manufactured by Custom Co., Ltd. is used, the range is L, the response is F, and the function is A, and the following method Then, measurement is performed in a measurement chamber where the sound generation level is 42 dB.
As shown in FIG. 1, on a steel caster 1 (W400 × L600 × H600), a sample 4 cut to a width of 180 mm × a length of 200 mm is fixed, and an iron pipe 3 (outer diameter 3.3 mmφ × length 130 mm) is used. Roll about 140 mm and reciprocate once while pressing strongly on the sample in the direction of the course row and the load with a palm so that the thickness is 20%. The rolling speed at this time is 50 cm / sec. The volume measuring sensor 2 is fixed in advance at a distance of 50 mm from the sample, and the maximum sound generation value for the forward movement and the maximum sound generation value for the backward movement are read to obtain an average value.

(2) 245N load tension compression deflection amount E (mm) and hysteresis loss rate Q (%) during tension compression deflection using a disk-shaped compression jig having a diameter of 100 mm for a three-dimensional knitted fabric
A square plate-shaped metal frame with legs 15cm high at the four corners and an inner diameter of 30cm and an outer diameter of 41cm per side (No. 40 sandpaper is attached to the upper surface to provide anti-slip properties) In order to prevent the three-dimensional knitted fabric from slacking between a rectangular plate-shaped metal frame having an inner diameter of 30 cm and an outer diameter of 41 cm (attaching sandpaper No. 40 on the lower surface to provide anti-slip properties) Clamp and fix the surrounding area with a vise.

Using a Shimadzu autograph AG-B type (manufactured by Shimadzu Corporation), the central part of the stretched three-dimensional knitted fabric was compressed at a speed of 50 mm / min with a circular planar compression jig having a diameter of 100 mm. When the load is reached, return to the original speed. From the load-displacement curve shown in FIG. 2 obtained at this time, the displacement of the three-dimensional knitted fabric at the time of 245N load is defined as a deflection amount E (mm). As shown in FIG. 2, the area formed by the compression curve 0A and the compression recovery curve A0 is a ₁ (cm ² ), and the area formed by the compression recovery curve A0, the straight line AB, and the straight line B0 is a ₂ (cm ² ). The hysteresis loss rate Q (%) is calculated by the following equation.
Q (%) = [a ₁ / (a ₁ + a ₂ )] × 100

(3) Adhesion amount of silicone oil The weight A ₀ per 400 cm ² before treatment with silicone oil and the weight A ₁ per 400 cm ² after treatment are measured and calculated according to the following formula. Is calculated.
Silicone oil adhesion amount (%) = [(A ₁ −A ₀ ) / A ₀ ] × 100

(4) Cushion characteristics (Kishimi sound when sitting, feeling of elasticity when sitting, feeling of bottoming after sitting, fit)
A three-dimensional knitted fabric is cut into a 40 cm square, and end portions are sewn to produce a cushion material. A cushion material for a chair is prepared by placing a solid knitted fabric as a cushion material on a chair (four legs, no backrest) made of a square metal plate having a seat shape of 40 cm square. On top of that, a man with a weight of 65 kg sits on a cushion material for a chair for 5 minutes and then leaves the seat for 1 minute 10 times.
The sensory evaluation of the squeaky sound at the moment of sitting (in contact with the solid knitted fabric), ◎: Not interested at all, ○: Almost not concerned, Δ: Slightly concerned, ×: Very anxious and uncomfortable Relative evaluation is performed in four stages of feeling.

Sensory evaluation of the feeling of elasticity at the moment of sitting (in contact with the three-dimensional knitted fabric), ◎: There is a feeling of elasticity, ○: Some feeling of elasticity, △: Some feeling of elasticity, ×: Little feeling of elasticity Relative evaluation is made in 4 stages.
At the same time, the soft feeling is evaluated by sensory evaluation. Relative evaluation is performed in four stages: ◎: soft, ○: slightly soft, Δ: slightly hard, ×: hard.
The sensory evaluation of the feeling of bottoming after sitting is as follows: ◎: feels no bottoming, ○: feels almost no bottoming, △: feels a slight feeling of bottoming, x: feels a feeling of bottoming intensely 4 Relative evaluation at each stage.
Relative evaluation is performed in four stages: ◎: high fit, ◯: slightly high fit, △: slightly low fit, ×: low fit.

(6) Appearance (look) and tactile feeling (stickiness) after sitting on cushion material
After the test of (5), according to the appearance observation of the dent state of the three-dimensional knitted fabric stretched on the chair, ◎: no dent, ◯: almost no dent, △: slightly dent, ×: severe dent 4 Relative evaluation at each stage.
The surface of the three-dimensional knitted fabric stretched on the chair was touched by hand, and the relative evaluation was made in four stages: ◎: not sticky at all, ○: hardly sticky, Δ: slightly sticky, ×: very sticky.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited only to an Example.

[Reference Example 1]
(Manufacture of polytrimethylene terephthalate monofilament)
The polytrimethylene terephthalate monofilament used in the examples was produced by the following method.
Polytrimethylene terephthalate of η _{sp / c} = 0.92 (measured at 35 ° C. using o-chlorophenol as a solvent) was discharged from the spinning nozzle at a spinning temperature of 265 ° C. This was led into a cooling bath at 40 ° C. and cooled, and the unstretched monofilament was pulled and thinned by the first roll group at a speed of 16.0 m / min. Next, the film was pulled by a second roll group of 80.0 m / min while being stretched 5 times in a stretching bath at a temperature of 55 ° C. Subsequently, while performing relaxation heat treatment in a steam bath at 120 ° C., the film is wound by a winder having the same speed as the third roll group through the third roll group of 72.0 m / min, and stretched by 390 dtex and 440 dtex A monofilament was produced.
The intrinsic viscosity [η] (dl / g) is a value obtained based on the definition of the following formula.
[Η] = lim (ηr−1) / C
C → 0
Ηr in the definition is obtained by dividing the viscosity of a diluted solution of polytrimethylene terephthalate yarn or polyethylene terephthalate yarn dissolved in an o-chlorophenol solvent with a purity of 98% or more at 35 ° C. by the viscosity of the solvent measured at the same temperature. Which is defined as relative viscosity. C is the polymer concentration expressed in g / 100 ml.

[Example 1]
Using a 14 gauge, 6mm double raschel knitting machine with 6 hooks, one side of two hooks (L1, L2) that form the knitted fabric on the front and two hooks that form the knitted fabric on the back From (L5), 501 dtex / 144 filament polyethylene terephthalate fiber false twisted yarn (Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement. All-in-one arrangement of monofilaments of 390 dtex polytrimethylene terephthalate fibers produced in Reference Example 1 from two single-side ridges (L6) forming the back surface and two single-side ridges (L3) forming the connecting portion Supplied with. A false twisted yarn of polyethylene terephthalate fiber of 167 dtex / 48 filament (manufactured by Asahi Kasei Co., Ltd., black dyed yarn) was supplied from the other ridge (L4) forming the connecting portion in an all-in arrangement.

With a knitting structure shown below, a three-dimensional knitted fabric machine was knitted at a density of 13.5 course driven / 2.54 cm. The obtained green machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 1.
(Knitting organization)
L1: 1011/2122/3233/3433/2322/121 /
L2: 3433/2322/1211/1011/2122/3233 /
L3: 1032/4523 /
L4: 1032/4523 /
L5: 1110/0001 /
L6: 4410/1145 /
The obtained three-dimensional knitted fabric had a sound generation level of 65 dB or less, did not feel uncomfortable due to generation of an annoying sound when sitting, and had good cushioning properties.

[Example 2]
Using a 14 gauge, 6mm double raschel knitting machine with 6 hooks, one side of two hooks (L1, L2) that form the knitted fabric on the front and two hooks that form the knitted fabric on the back From (L5), 501 dtex / 144 filament polyethylene terephthalate fiber false twisted yarn (Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement. Monofilaments of 390 dtex polytrimethylene terephthalate fibers produced in Reference Example 1 were supplied in an all-in arrangement from two ridges (L6) forming the back side. Monofilaments of 440 dtex polytrimethylene terephthalate fibers produced in Reference Example 1 were supplied in an all-in arrangement from the two ridges (L3) forming the connecting portion. From the other ridge (L4) forming the connecting portion, an 84 dtex / 24 filament polyethylene terephthalate fiber false twisted yarn (manufactured by Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement.

With a knitting structure shown below, a three-dimensional knitted fabric machine was knitted at a density of 13.5 course driven / 2.54 cm. The obtained green machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 1.
(Knitting organization)
L1: 1011/2122/3233/3433/2322/121 /
L2: 3433/2322/1211/1011/2122/3233 /
L3: 1032/4523 /
L4: 1032/4523 /
L5: 1110/0001 /
L6: 4410/1145 /
The obtained three-dimensional knitted fabric had a sound generation level of 65 dB or less, did not feel uncomfortable due to generation of an annoying sound when sitting, and had good cushioning properties.

[Example 3]
Using a 14 gauge, 6mm double raschel knitting machine with 6 hooks, one side of two hooks (L1, L2) that form the knitted fabric on the front and two hooks that form the knitted fabric on the back From (L5), 501 dtex / 144 filament polyethylene terephthalate fiber false twisted yarn (Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement. Monofilaments of 390 dtex polytrimethylene terephthalate fibers produced in Reference Example 1 were supplied in an all-in arrangement from two ridges (L6) forming the back side. Monofilaments of 440 dtex polytrimethylene terephthalate fibers produced in Reference Example 1 were supplied in an all-in arrangement from the two ridges (L3) forming the connecting portion. From the other ridge (L4) forming the connecting portion, an 84 dtex / 24 filament polyethylene terephthalate fiber false twisted yarn (manufactured by Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement.

With a knitting structure shown below, a three-dimensional knitted fabric machine was knitted at a density of 13.5 course driven / 2.54 cm. The obtained green machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 1.
(Knitting organization)
L1: 1011/2122/3233/3433/2322/121 /
L2: 3433/2322/1211/1011/2122/3233 /
L3: 1032/4523 /
L4: 4523/1032 /
L5: 1110/0001 /
L6: 4410/1145 /
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Example 4]
Using a 14-gauge, 15-mm double raschel knitting machine equipped with 6 ridges, two ridges (L1, L2) that form the knitted fabric on the front side and two ridges that form the knitted fabric on the back side From (L5), 501 dtex / 144 filament polyethylene terephthalate fiber false twisted yarn (made by Asahi Kasei Co., Ltd., black dyed yarn) 2 in 2 out (L1), 2 out 2 in (L2) and all in Supplied in the sequence (L5). All-in arrangement of monofilaments of 390 dtex polytrimethylene terephthalate fiber produced in Reference Example 1 from two single-side ridges (L3) forming the connecting portion and two single-side ridges (L6) forming the back surface Supplied with. All the 167 dtex / 48 filament polyethylene terephthalate fiber false twisted yarn (made by Asahi Kasei Co., Ltd., black dyed yarn) from the two single-side ridges (L4) forming the connecting part. Supplied.

With a knitting structure shown below, a three-dimensional knitted fabric machine was knitted at a density of 13.5 course driven / 2.54 cm. The obtained raw machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric in which the surface knitted fabric was mesh and the back knitted fabric was flat. Table 1 shows various physical properties of the obtained three-dimensional knitted fabric.
(Knitting organization)
L1: 1011/3233/4544/2322 /
L2: 4544/3322/0111/2333 /
L3: 1032/4523 /
L4: 1032/4523 /
L5: 1110/0001 /
L6: 3310/1134 /
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Example 5]
The living machine obtained in Example 1 was immersed for 1 minute in a solution prepared by adjusting a reactive amino-modified silicone emulsion (manufactured by Asahi Kasei Wacker Silicone Co., Ltd., trade name CT45E) as a silicone-based oil agent to a solution concentration of 1.0 wt%. The solution was squeezed with a mangle squeezer at a mangle pressure of 0.5 MPa and a processing speed of 5 m / min. The raw machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a solid knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 1.
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Example 6]
Using a 14 gauge, 13 mm double raschel knitting machine equipped with 6 ridges, one side of two ridges (L1, L2) that form the knitted fabric on the front side and two ridges that form the knitted fabric on the back side From (L5), 501 dtex / 144 filament polyethylene terephthalate fiber false twisted yarn (Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement. 1 in 1 out (L3) monofilament of 390 dtex polytrimethylene terephthalate fiber produced in Reference Example 1 from two ridges (L3, L4) forming the connecting portion and the other ridge (L6) forming the back surface. ), 1 out 1 in (L4) and all in (L6) sequences.

With a knitting structure shown below, a three-dimensional knitted fabric machine was knitted at a density of 13.5 course driven / 2.54 cm. A reactive amino-modified silicone emulsion (manufactured by Asahi Kasei Wacker Silicone Co., Ltd., trade name: CT45E) was immersed in a solution adjusted to a solution concentration of 5.0 wt% for 1 minute using the obtained raw machine as a silicone oil. The solution was squeezed with a mangle squeezer at a mangle pressure of 0.5 MPa and a processing speed of 5 m / min. The raw machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a solid knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 2.
(Knitting organization)
L1: 1011/2122/3233/3433/2322/121 /
L2: 3433/2322/1211/1011/2122/3233 /
L3: 1032/4523 /
L4: 4523/1032 /
L5: 1110/0001 /
L6: 3310/1134 /
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Example 7]
The living machine obtained in Example 6 was immersed for 1 minute in a solution prepared by adjusting a reactive amino-modified silicone emulsion (trade name: CT45E, manufactured by Asahi Kasei Wacker Silicone Co., Ltd.) as a silicone oil to a solution concentration of 1.0 wt%. The solution was squeezed with a mangle squeezer at a mangle pressure of 0.5 MPa and a processing speed of 5 m / min. The raw machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a solid knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 2.
As a result of measuring sound generation, the obtained three-dimensional knitted fabric had a sound generation level of 65 dB or less, did not feel uncomfortable due to generation of harsh sounds when sitting, and had good cushioning properties.

[Example 8]
The raw machine obtained in Example 1 was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric with flat front and back knitted fabrics. A three-dimensional knitted fabric obtained by cutting polytrimethylene terephthalate fibers having a single yarn fineness of 1.7 dtex into a length of 2 mm was sufficiently adhered to the surface of the three-dimensional knitted fabric and the connecting yarn by flocking. The physical properties are shown in Table 2.
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Example 9]
The raw machine obtained in Example 5 was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a three-dimensional knitted fabric with flat front and back knitted fabrics. A three-dimensional knitted fabric obtained by cutting polytrimethylene terephthalate fibers having a single yarn fineness of 1.7 dtex into a length of 2 mm was sufficiently adhered to the surface of the three-dimensional knitted fabric and the connecting yarn by flocking. The physical properties are shown in Table 2.
The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less, and it did not feel uncomfortable due to generation of annoying sound when sitting, and the cushioning property was also good.

[Comparative Example 1]
In Example 1, instead of two single-side ridges (L4) forming a connecting yarn, false twisted yarn of polyethylene terephthalate fiber of 167 dtex / 48 filament (made by Asahi Kasei Corporation, black dyed yarn) A three-dimensional knitted fabric was obtained in the same manner as in Example 1 except that a monofilament of 390 dtex polytrimethylene terephthalate fiber was supplied in an all-in arrangement.
Table 3 shows various physical properties of the obtained three-dimensional knitted fabric. The sound generation level of the obtained three-dimensional knitted fabric was higher than 65 dB. Although the cushioning was good, it felt uncomfortable due to the generation of harsh sounds when sitting.

[Comparative Example 2]
In Example 1, 390 dtex of 167 dtex / 48 filament polyethylene terephthalate fiber false twisted yarn (manufactured by Asahi Kasei Co., Ltd., black dyed yarn) from two single-side ridges (L4) forming the connecting yarn A solid knitted fabric was obtained in the same manner as in Example 1 except that a polytrimethylene terephthalate fiber monofilament and a 167 dtex / 48 filament polyethylene terephthalate fiber false twisted yarn were supplied in an all-in arrangement.
Table 3 shows various physical properties of the obtained three-dimensional knitted fabric. The sound generation level of the obtained three-dimensional knitted fabric was higher than 65 dB. Although the cushioning property was good, it felt uncomfortable due to the generation of harsh sounds when sitting.

[Comparative Example 3]
In Example 1, false twisted yarn (manufactured by Asahi Kasei Co., Ltd.) of monofilaments of polytrimethylene terephthalate fibers of 390 dtex and polyethylene terephthalate fibers of 167 dtex / 48 filaments from two halves (L3) forming the connecting yarn. , Black dyed yarn) was obtained in the same manner as in Example 1 except that it was alternately fed in an all-in arrangement for each one.
Table 3 shows various physical properties of the obtained three-dimensional knitted fabric. The sound generation level of the obtained three-dimensional knitted fabric was 65 dB or less. Although there was no discomfort due to the generation of harsh sounds when sitting, recovery was poor and good cushioning could not be obtained.

[Comparative Example 4]
In Example 1, instead of the two single-side ridges (L4) forming the connecting yarn, a false twisted yarn of polyethylene terephthalate fiber of 167 dtex / 48 filament (manufactured by Asahi Kasei Corporation, black dyed yarn) A three-dimensional knitted fabric was obtained in the same manner as in Example 1 except that 167 dtex / 6 filament polyethylene terephthalate fiber false twisted yarn (Asahi Kasei Co., Ltd., black dyed yarn) was supplied in an all-in arrangement.
Table 3 shows various physical properties of the obtained three-dimensional knitted fabric. The sound generation level of the obtained three-dimensional knitted fabric was higher than 65 dB. Although the cushioning property was good, it felt uncomfortable due to the generation of harsh sounds when sitting.

[Comparative Example 5]
In Example 5, a reactive amino-modified silicone emulsion (manufactured by Asahi Kasei Wacker Silicone Co., Ltd., trade name: CT45E) was immersed for 1 minute in a solution adjusted to a solution concentration of 0.01 wt% using the obtained raw machine as a silicone-based oil. The solution was squeezed with a mangle squeezer at a mangle pressure of 0.5 MPa and a processing speed of 5 m / min. The raw machine was widened by 15% and heat-heat set at 150 ° C. for 3 minutes to obtain a solid knitted fabric with flat front and back knitted fabrics. The physical properties are shown in Table 3.
The sound generation level of the obtained three-dimensional knitted fabric was higher than 65 dB. Although the cushioning property was good, it felt uncomfortable due to the generation of harsh sounds when sitting.

  The three-dimensional knitted fabric of the present invention is suitably used for seats for automobiles, railway vehicles, aircrafts, child seats, strollers, wheelchairs, furniture, offices and the like. In particular, it is suitable for the cushion material of these seats.

It is a schematic diagram of the measuring device of a sound generation level. It is a graph which shows a tension compression compression load-displacement curve.

Claims (6)

  A three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and a connecting layer comprising connecting yarns connecting the two knitted fabrics, and the sound generation level when compressing the three-dimensional knitted fabric is 65 dB or less, a monofilament And multifilaments are knitted at the time of knitting to form a connecting yarn, the multifilament weight mixing ratio in the connecting yarn is 10% to 50%, and the single filament fineness of the multifilament is 20 dtex or less. Three-dimensional knitting.   The 245N load tension compression deflection amount using a disk-shaped compression jig with a diameter of 100 mm of a three-dimensional knitted fabric is 15 mm or more and 80 mm or less, and hysteresis loss at the time of 245N load tension compression deflection using a disk-shaped compression jig with a diameter of 100 mm The three-dimensional knitted fabric according to claim 1, wherein the rate is 70% or less.   The three-dimensional knitted fabric according to claim 1 or 2, wherein the silicone oil is adhered to the solid knitted fabric in a solid content of 0.05 wt% or more and 5.0 wt% or less.   The three-dimensional knitted fabric according to claim 1 or 2, wherein fibers having a single yarn fineness of 0.1 dtex or more and 10 dtex or less are adhered to the three-dimensional knitted fabric by a flocking process.   The three-dimensional knitted fabric for seats according to any one of claims 1 to 4.   A three-dimensional knitted fabric for a seat according to claim 5 is used as a cushion material for a back portion and / or a seat portion.

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