JP2005226167A - Double weft knitted fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a double weft knitted fabric having unevennesses as if the unevennesses were formed by emboss processing on the surface, scarcely crushing protruding parts thereof, forming the whole into a hard platy shape as if the fabric were laminated onto a substrate, stabilizing the shape and suitable for ceiling materials, wall surface materials or other interior materials of buildings, ships, vehicles, etc., surface materials, etc., of indoor equipment articles such as furniture or partitions. <P>SOLUTION: The double weft knitted fabric is doubly composed of a right side knitted fabric and a lining knitted fabric. In the double weft knitted fabric, inserting yarns D continuous in one straight-line form in the course direction are knitted between the right side knitted fabric 11 and the lining knitted fabric 12. Furthermore, the right side knitted fabric 11 and the lining knitted fabric 12 are partially connected to form unevennesses of connected parts 13 into recessed parts 15 and the residual unconnected parts 14 into protruding parts 16 on the surface of the double weft knitted fabric. Fibers of the inserting yarns D are filled in the interior of the protruding parts 16. Thermally fusible fibers and thermally nonfusible fibers are used in the right side knitted fabric 11 and thermally fusible fibers are used in the lining knitted fabric 12. After knitting the double weft knitted fabric, the thermally fusible fibers are fused by heating. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a double weft knitted fabric used as a ceiling material of a building, a ship, a vehicle or the like, a wall surface material or other interior material, or a surface material of indoor equipment such as furniture or a partition.

In a double raschel warp knitting machine, a double warp knitted fabric knitted by connecting a front knitted fabric knitted with a front warp yarn and a front insertion yarn and a back knitted fabric knitted with a back warp yarn and a back insertion yarn with a connecting yarn The front and back warp yarns form chain stitches to form a string-like chain stitch row that continues in the wale direction, and the front and back insertion yarns penetrate through the plurality of string-like chain stitch rows formed by the front and back warp yarns, respectively. Since it is connected and extends in the course direction, the knitted structure structure of the knitted fabric on the front and back approximates the woven structure structure of the woven fabric in which the warp and weft are orthogonal, and the shape of the knitted fabric on the front and back is similar to the woven fabric and is stable. The connecting yarn is in an upright state between the front and back knitted fabrics and perpendicular to the front and back knitted fabrics, and the whole has a plate-like three-dimensional structure that is difficult to bend, and is excellent in cushioning and sound absorption It is known to use it as an interior material (for example, Patent Document 1) Reference 2 and 3 and 4). As a method of drawing a concavo-convex pattern on the surface of the fabric, the surface and lining of the double fabric consisting of several types of yarns with different shrinkage are partially connected in a pattern and subjected to shrinkage treatment, resulting from shrinkage difference It is publicly known to generate irregularities on the front or back (see, for example, Patent Documents 5 and 6). An interior material obtained by embossing a cloth on a plastic foam sheet is known (see, for example, Patent Documents 7 and 8).
JP-A-5-148746. JP-A-5-269899. JP-A-6-305064. JP2003-013346A. Japanese Examined Patent Publication No. 2-52024 (Japanese Patent Laid-Open No. 63-182445). Japanese Patent Publication No. 6-63156 (JP-A-4-370241). Japanese Patent Publication No. 60-58022 (Japanese Patent Laid-Open No. 56-167437). Japanese Patent Publication No. 60-58023 (Japanese Patent Laid-Open No. 57-255942).

  The double warp knitted fabric used for the interior material originally cuts the connecting yarn between the front knitted fabric and the back knitted fabric, and in the process of simultaneously manufacturing two cut pile fabrics based on the front and back knitted fabrics. It is knitted as an intermediate product, and the back side of the manufactured cut-pile fabric is the same as a plain and plain general warp knitted fabric. Absent. Even if you try to emboss the double warp knitted fabric to give it a commercial value as an interior material, it will have the same strong resilience as a pile from the connecting yarn that exists between the front and back knitted fabrics. Since it is received, it cannot be embossed. Even if it is strongly embossed, the fibers are fused and formed into a film shape in the formed recess, and the texture as a fabric is impaired. Such a defect is the same when embossing is performed by overlaying a fabric on a plastic foam sheet having closed cells and suitable for embossing.

  In a double fabric in which a double fabric consisting of a surface and a lining having different shrinkage properties is subjected to a shrinking treatment and an uneven pattern resulting from a low shrinkage difference is formed on the surface or the lining, the inside of the formed convex portion is the surface and the lining. Therefore, the convex portion is easily crushed. The double fabric thus shaped is merely thickened by the thickness of the convex portion, and the flexibility of the double fabric is changed by the shrinkage treatment, thereby improving the shape stability. There is no increase.

  Therefore, the present invention has irregularities as if formed on the surface by embossing, the convex portions are hard to be crushed, the whole is hard and plate-like as if it was bonded to the substrate, and the shape is stable, It is an object of the present invention to obtain a double fabric suitable for ceiling materials such as buildings, ships and vehicles, wall materials and other interior materials, and surface materials for indoor equipment such as furniture and partitions.

  The double weft knitted fabric according to the present invention is constituted by a front knitted fabric and a back knitted fabric in a double manner, and an insertion yarn D that continues in a straight line in the course direction is knitted between the front knitted fabric 11 and the back knitted fabric 12. The front knitted fabric 11 and the back knitted fabric 12 are partially connected to each other, the connecting portion 13 constitutes a recess 15, and the remaining non-connecting portion 14 other than the connecting portion is formed. Convex portion 16 is formed, and the inside of convex portion 16 surrounded by the front knitted fabric and the back knitted fabric is filled with fibers of insertion yarn D, and front knitted fabric 11 is made of heat-fusible fibers and non-heat-fusion. The first characteristic is that it contains adhesive fibers, the knitted fabric 12 contains heat-fusible fibers, and these heat-fusible fibers are fused.

  The second feature of the double weft knitted fabric according to the present invention is that, in addition to the first feature, the thickness of the concave portion 15 is 0.5 mm or more, and the thickness of the convex portion 16 is 1. It is in the point which is 3 times.

  A third feature of the double weft knitted fabric according to the present invention is that, in addition to any of the first and second features, the convex portion 16 is continuous in at least one of the course direction and the wale direction. 17 is formed.

  The fourth feature of the double weft knitted fabric according to the present invention is that, in addition to any of the first, second and third features, the content of the heat-fusible fiber contained in the back knitted fabric 12 is as follows. More than the content of the heat-fusible fiber contained in the front knitted fabric 11, the content of the heat-fusible fiber contained in the back knitted fabric 12 is 10% by weight or more.

  A fifth feature of the double weft knitted fabric according to the present invention is that, in addition to any of the first, second, third, and fourth features, the heat-fusible fiber is not a heat-fusible polymer. This is a composite fiber made of a heat-fusible polymer.

  The sixth feature of the double weft knitted fabric according to the present invention is knitted into the double weft knitted fabric in addition to any of the first, second, third, fourth, and fifth features. The reduction rate (L / W) of the insertion yarn D is 1.1 or more (L / W ≧ 1.1).

  According to the present invention (Claim 1), the inside of the gap formed between the front knitted fabric 11 and the back knitted fabric 12 of the convex portion 16 is filled in the fiber of the insertion yarn, and the heat-fusible fiber is fused. Since the shape of the stitches of the convex portion 16 is fixedly set, the convex portion 16 is not easily crushed. Then, the heat-fusible fiber is fused and the shape of the stitch is fixed and set, the stretchability and flexibility as the knitted fabric are suppressed, and the front knitted fabric 11 and the back knitted fabric 12 are finished in a hard plate shape. The entire knitted fabric 11 and the back knitted fabric 12 are separated from each other by the thickness corresponding to the thickness of the convex portion 16, and the distance (thickness) between the front knitted fabric 11 and the back knitted fabric 12 is kept constant. No sagging or peeling occurs between the front knitted fabric 11 and the back knitted fabric 12. The appearance and tactile feel of the surface knitted fabric 11 as a knitted fabric are maintained by the non-heat-fusible fibers mixed therein. For this reason, the double weft knitted fabric of the present invention is hard and plate-like, has a stable shape, and is used indoors for ceiling materials, wall materials and other interior materials for buildings, ships, vehicles, etc., furniture, partitions, etc. It will be suitable for the surface material of equipment. Even if it is so hard and plate-like, the heat-fusible fiber is softened by heating, and the stretchable flexibility as enormous in the heated state is restored. It can be easily mounted along the curved surface of the interior base, furniture, or partition frame, and can be thermoformed.

  According to the present invention (Claim 2), the shape is stable and the plate shape is formed as if the surface knitted fabric 11 is bonded to the plastic foam plate material having a thickness corresponding to the thickness of the convex portion 16 and embossed. Thus, a double weft knitted fabric having a knitted appearance and a tactile feel can be obtained.

  According to the present invention (Claim 3), the ridges 17 in which the convex portions 16 in the double weft knitted fabric, in which the heat-fusible fiber is fused and finished as a whole, are formed in a continuous manner, are of one kind. It has a reinforcing function as a rib. For this reason, the double weft knitted fabric of the present invention increases the shape stability in the direction in which the convex portions 16 are continuous, is difficult to bend, and is laid between the frame material and the frame material constituting the interior base. It is also possible.

  According to the present invention (Claim 4), the stitch of the back knitted fabric 12 to which the heat-fusible fibers are fused appears at first glance as a bubble of a plastic foam sheet. The back side is beautifully finished. Then, since the fused heat-fusible fibers are present on the surface of the back knitted fabric 12, the double weft knitted fabric of the present invention can be applied by heating and bonding to an interior base or the like.

  According to the present invention (Claim 5), even if the heat-fusible fiber is fused, if it is a composite fiber composed of a heat-fusible polymer and a non-heat-fusible polymer, the non-heat The form as a fiber is maintained by the fusible polymer, and the double weft knitted fabric is not deformed into a film shape by the fusion, and the appearance as the double weft knitted fabric is maintained.

  According to the present invention (Claim 6), the double weft knitted fabric is very large and small in flexibility, and when it is removed from the tension state in the knitting process after being removed from the knitting machine, the whole shrinks and the course direction The shrinkage ratio L / W of the insertion yarn D inserted in a straight line is increased from 1.0 in the tension state, and the bulge is increased in the inside of the convex portion 16, whereby the front knitted fabric 11 and the back knitted fabric of the convex portion 16 are increased. Since the space between 12 is spread and fixed with heat-fusible fibers fused as it is, the convex portion 16 is not easily crushed, and a double weft knitted fabric rich in cushioning properties is obtained.

  The double weft knitted fabric of the present invention will be described in more detail. (A) In a double weft knitting machine in which needles (knitting needles) are divided into a front knitted fabric and a back knitted fabric and arranged in two rows, a plurality of types Types of knitting yarns (A, B, C, D ...) are selectively supplied to the front and back knitting needles To form a double weft knitted fabric in which the front knitted fabric 11 and the back knitted fabric 12 are front and back, and (b) at least one of the plural types of knitting yarns (A, B, C, D...) One type of knitting yarn (D) is inserted as an insertion yarn between the front knitted fabric 11 and the back knitted fabric 12 every 1 to 6 courses, and is continuous in a straight line in the course direction. (C) Table At least one kind of surface knitted fabric 11 that forms a plurality of types of knitting yarns (A, B, C,...) Selectively supplied to the knitted fabric needle and the back knitted fabric needle. At least one of the yarn (B) and at least one type of knitting yarn (C) that will form the back knitted fabric 12 is transferred from the front knitted fabric 11 to be formed. Move to the knitted fabric 12 to form the stitch of the back knitted fabric, or move from the back knitted fabric 12 to the front knitted fabric 11 to form the stitch of the front knitted fabric, and then the remaining knitting yarn (A C) The front knitted fabric 11 and the back knitted fabric 12 formed by C) are connected, and the connecting portion 13 forms a recessed portion 15 that is recessed, and (d) the insertion yarn that is inserted and continues in a straight line (D ) Is fastened to the knitting yarn (B) connecting the front knitted fabric 11 and the back knitted fabric 12 in the concave portion 15 (connecting portion 13), and the fiber density of the insertion yarn (D) becomes dense. (E) In the non-connecting portion 14 other than the concave portion not connected to the knitting yarn (B), the insertion yarn (D) bulges and appears. The space between the ground and the back knitted fabric is expanded to form a convex portion 16 opposite to the concave portion 15, and the inside of the convex portion 16 is filled with a bulky insertion thread (D), and (f) Table At least a part of the knitting yarn (B) constituting the knitted fabric 11 and at least a part of the knitting yarn (C) constituting the back knitted fabric 12 contain a heat-fusible fiber, and (g) the heat fusion The knitting yarn (B) containing adhesive fibers connects the front knitted fabric 11 and the back knitted fabric 12 in the recess 15, and (h) the heat-fusible fibers contained in the knitting yarn (B / C) are melted. The double weft knitted fabric is restrained to be flexible, thereby imparting shape stability to maintain the double weft knitted fabric in a plate-like shape. The fibers constituting D) have crimps (crimps).

  The shrinkage ratio (L / W) of the insertion yarn (D) is the dimension in the course direction of the double weft knitted fabric obtained by heat-treating the heat-fusible fiber of the knitting yarn (B / C). (W) is calculated as a value (L / W) obtained by dividing the length (L) in a state where a tension of 4.1 gf / dtex is applied to the insertion thread (D) taken out from the part corresponding to the dimension. Is done. As the knitting yarn, especially the knitting yarn (C) for the knitted fabric, it is preferable to use a fire-resistant fiber such as glass fiber, aramid fiber or fitting fiber, and the heat-fusible fiber is a knitting yarn mainly composed of the fire-resistant fiber. Used together. In that case, it is good to use a flame-retardant fiber for insertion thread (D) and to give a flame-retardant treatment with a flame retardant. In order to make the double weft knitted fabric flame retardant, it is preferable to apply a flame retardant on the back surface, or to bond paper, fabric, fiber reinforced plastic or the like carrying the flame retardant on the back surface.

  Apply various types of knitting yarns (AB) to the surface knitted fabric and selectively supply them to the needle for the surface knitted fabric to draw various designs on the surface knitted fabric I can do it. To draw a variety of patterns on the front knitted fabric, change the colors of the knitted yarn (A ... B) of the front knitted fabric and the knitted yarn (C .........) of the back knitted fabric, Move the knitting yarn (A / B .........) to the back knitted fabric, move the knitting yarn (C .........) of the front knitted fabric to the front knitted fabric, and connect the front knitted fabric and the back knitted fabric. In this way, the front knitted fabric (A ... B) and the back knitted fabric (C ...) are exchanged between the front and back at the connecting portion 13 so that the color of the front knitted fabric and the color of the back knitted fabric are changed. May be changed. When such front / back replacement of the knitting yarn is performed only at the connecting portion 13, the concave portion 15 and the convex portion 16 are color-coded.

  The double weft knitted fabric is removed from the knitting machine, released from the tension state in the knitting process, and contracted as a whole. For that purpose, the knitting yarns (A, B, C, etc.) have a reduction ratio (L / W) of 1.2 or more, preferably about 1.5 (1.45 to 1.55). ) And insertion yarn (D) are preferably crimped multifilament yarns that have crimps and are highly stretchable, and more preferably knitting yarns (A, B, C,...) And insertion yarns. Use water-shrinkable fibers or heat-shrinkable fibers for the yarn (D), and pass through a tumbler to loosen the knitting yarn (A / B / C ...) and the insertion yarn (D) to shrink the double weft knitted fabric Prompt. The heat treatment for fixing and setting the stitches by fusing the heat-fusible fibers is performed after the shrinkage treatment. When water-shrinkable fibers or heat-shrinkable fibers are mixed in the insertion yarn (D), the mixing ratio is 10% by weight or less. This is because a yarn made of 100% shrinkable fiber is merely shrunk to change its length and does not bulge to a particularly high bulk. The thickness (total fineness) of the insertion yarn (D) is preferably at least four times the thickness of the knitting yarn (A / B / C...). After the shrinking treatment, the stitches can be fixedly set by applying an adhesive resin to the double weft knitted fabric. In that case, in order not to impair the texture of the front knitted fabric, the adhesive resin may be applied only to the back knitted fabric. The content of the heat-fusible fiber contained in the surface knitted fabric 11 is 10% by weight or more, preferably 15 to 25% by weight. The content of the heat-fusible fiber contained in the back knitted fabric 12 is 20 to 40% by weight, more than the content of the heat-fusible fiber contained in the surface knitted fabric 11, by 10% by weight or more. The content of the heat-fusible fiber with respect to the total fabric weight of 11 and the back knitted fabric 12 is 60% by weight or less, preferably 50% by weight or less (20 to 40% by weight).

In a 20 gauge / 25.4 mm (inch) double jersey circular knitting machine, two types of knitting yarns A and B are supplied to the cylinder needles (F ₁ , F ₂ , F _3. organized, one knitting yarn C the dial needles _{(B 1 · B 2 · B} 3 .........) the insertion yarns D cylinder needle and the dial needle 3 each course of knitting the Urahen land 12 is supplied to the Supplied in between, the knitting yarn B for the knitted fabric is supplied to the cylinder needle and the dial needle in one course of the three courses, and the outer knitted fabric and the back knitted fabric are spread over 12 courses (H) every 3 courses (G). The front knitted fabric and the back knitted fabric are connected to the connecting portion 13 every 12 wales (K) every 4 wales (M), and the unconnected portion 14 between the three courses (G) A concave portion 15 formed by the connecting portion 13 is formed on the convex portion 16 formed by the non-connecting portion 14 between the four wales (J). Surrounded by the shape, the convex portion 16 formed by the non-connecting portion 14 has a half pitch (P / 2) in the wale direction at the position of the concave portion 15 formed by the connecting portion 13 at the boundary of the flange 17 that continues in the wale direction. Shift to form a double weft knitted fabric.

  For the knitting yarn A, a dyed polyester multifilament processed yarn of 330 dtex / 96f is used. For the knitting yarn B, a heat-fusible multifilament yarn of 280 dtex / 48f, which is a composite fiber having a low melting point polyester (melting point of about 160 ° C.) as a sheath component and a high melting point polyester having a melting point of 240 ° C. or more as a core component, is used. To do. As the knitting yarn C, 560 dtex / 96f, which is a composite fiber having a low melting point polyester (melting point: about 160 ° C.) as a sheath component and a high melting point polyester having a melting point of 240 ° C. or more as a core component, is used. As the insertion yarn D, a 1300 dtex / 384 f Wool false twisted polyester multifilament yarn is used.

FIG. 1 illustrates a boundary portion between a connecting portion 13 and a non-connecting portion 14 of a double weft knitted fabric, and FIG. 2 illustrates a knitting structure of the boundary portion. Double weft knitted fabric has 6 courses (C ₁ , C ₂ , C ₃ , C ₄ , C ₅ , C ₆ ) as a repeat, and cylinder needles facing each other (F ₁ , F ₂ , F ₃ ............ F ₁₀ ) and dial needles (B ₁ , B ₂ , B ₃ ... B ₁₀ ) are knitted by supplying knitting yarns A, B, and C as follows.
[First Course C ₁ ]
The knitting yarn B is supplied to the knitting needles F ₁ , B ₁ , B ₂ , F ₃ , B ₄ , F ₅ , F ₇ , F ₉ , and the knitting needles B ₁ and B ₃ are connected to the knitting needle B ₂ in the third course C ₃ . B ₄ forms a knit loop in the fourth course C ₄ , and the knitting needles F ₁ , F ₃ , F ₅ , F ₇ and F ₉ form a knit loop in the fifth course C ₅ , respectively.
[Second course C ₂ ]
The knitting yarn A is supplied to the knitting needles F ₂ , F ₄ , F ₆ , F ₈ , F ₁₀ , and these knitting needles form knit loops in the fourth course C ₄ , respectively.
[Third course C ₃ ]
The knitting yarn C is supplied to the knitting needles B ₁ , B ₃ , B ₅ , B ₇ , B ₉ , and these knitting needles form knit loops in the first course C ₁ , respectively.
Fourth Course C _4]
The knitting yarn B is supplied to the knitting needles B ₁ , F ₂ , B ₂ , B ₃ , F ₄ , B ₄ , F ₆ , F ₈ , F ₁₀ , and the knitting needles B ₁ and B ₃ are knitting needles in the first course C ₁ . B ₂ and B ₄ form a knit loop in the sixth course C ₆ , and the knitting needles F ₂ , F ₄ , F ₆ , F ₈ and F ₁₀ form a knit loop in the second course C ₂ , respectively.
Fifth course C _5]
The knitting yarn A is supplied to the knitting needles F ₁ , F ₃ , F ₅ , F ₇ , and F ₉ , and these knitting needles form knit loops in the first course C ₁ , respectively.
Sixth course C _6]
The knitting yarn C is supplied to the knitting needles B ₂ , B ₄ , B ₆ , B ₈ , B _{10. The} knitting needles B ₂ , B ₄ are in the first course C ₁ , and the knitting needles B ₆ , B ₈ , B ₁₀ are in the sixth course. At C ₆ , a knit loop is formed.

The connecting portion 13 is formed by cylinder needles (F _{1 to} F ₄ ) and dial needles (B _{1 to} B ₄ ), and the surface knitted fabric 11 of the non-connecting portion 14 is knitted by the cylinder needles (F _{5 to} F ₁₀ ). The back knitted fabric 12 of the non-connecting portion 14 is knitted by dial needles (B _{5 to} B ₁₀ ).

  The wale density of the double weft knitted fabric taken out of the knitting machine and under no tension was 23 wale / 25.4 mm (inch), and the course density was 34 course / 25.4 mm (inch). The double weft knitted fabric was passed through a tumbler dryer (100 ° C.), subjected to a relaxation shrinkage treatment, and subjected to a heat fixing set treatment at 170 ° C. The double weft knitted fabric thus obtained has a course density of 28 courses / 25.4 mm (inches), a wale density of 32 wales / 25.4 mm (inches), and a concave portion 15 having a thickness of 1.0 mm and convex. The thickness of the portion 16 was 3.0 mm, and the reduction rate (L / W) of the insertion yarn D was 1.54. Double weft knitted fabric is hard and plate-like, can be supported with one end fixed in the shape of a cantilever, and should be constructed between the frame material that constitutes the interior base, etc. It was suitable as a ceiling material or a wall material.

It is a partially cut away enlarged surface view of the double weft knitted fabric according to the present invention. 1 is a knitting organization chart of a double weft knitted fabric according to the present invention. 1 is a perspective view of a double weft knitted fabric according to the present invention.

Explanation of symbols

11: Front knitted fabric 12: Back knitted fabric 13: Connection portion 14: Non-connection portion 15: Concave portion 16: Convex portion 17: 畝 A / B / C: Knitting yarn D: Insertion yarn

Claims (6)

  The front knitted fabric and the back knitted fabric are doubled, and the insertion yarn (D) that continues in a straight line in the course direction is knitted between the front knitted fabric (11) and the back knitted fabric (12). The ground (11) and the back knitted fabric (12) are partially connected, and the connecting part (13) forms a recess (15), and the remaining non-connected parts other than the connecting part The portion (14) constitutes a convex portion (16), and the inside of the convex portion (16) surrounded by the front knitted fabric and the back knitted fabric is filled with the fibers of the insertion yarn (D). (11) contains heat-fusible fibers and non-heat-fusible fibers, and the back knitted fabric (12) contains heat-fusible fibers, and these heat-fusible fibers are fused. Double weft knitted fabric.   The double weft knitted fabric according to claim 1, wherein the thickness of the concave portion (15) is 0.5 mm or more, and the thickness of the convex portion (16) is 1.3 times or more the thickness of the concave portion (15).   The double weft knitted fabric according to claim 1 and 2, wherein the convex portion (16) forms a reed (17) continuous in at least one of the course direction and the wale direction.   The content of the heat-fusible fiber contained in the back knitted fabric (12) is larger than the content of the heat-fusible fiber contained in the front knitted fabric (11), and the heat contained in the back knitted fabric (12). 4. The double weft knitted fabric according to claim 1, wherein the content of the fusible fiber is 10% by weight or more.   5. The double weft knitted fabric according to claim 1, wherein the heat-fusible fiber is a composite fiber made of a heat-fusible polymer and a non-heat-fusible polymer.   The first, second, third, fourth, and fifth, fifth, fourth, and fifth aspects of the present invention, wherein the reduction ratio (L / W) of the insertion yarn (D) knitted into the double weft knitted fabric is 1.1 or more. Double weft knitted fabric as described in.

Images