JP2006219785A - Sewed product of three-dimensional knit - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sewed product of a three-dimensional knit which is obtained by connecting a laminate using the three-dimensional knit as a part, and which has excellent pressure-dispersing performance, and feeling of oneness of the laminate part. <P>SOLUTION: The sewed product is obtained by connecting a laminate using as a part the three-dimensional knit constituted of front and back two layers of knits and a connecting yarn for connecting the two layers of the knits. The number of connections per square meter of the part at which the three-dimensional knit is used is ≥1 and ≤100 in the sewed product of the three-dimensional knit. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a three-dimensional knitted fabric product in which a laminate using at least a part of a three-dimensional knitted fabric is joined.

Since the three-dimensional knitted fabric has excellent breathability and cushioning properties, it is used as various cushioning materials, and is used, for example, as a bed pad or a seat cushion of a chair. When used for such applications, quilting is performed for the purpose of providing a three-dimensional shape, stacking three-dimensional knitted fabrics to improve cushioning properties, and stacking with materials other than three-dimensional knitted fabrics. There is a case.
However, when quilting sewing is performed, the cushioning function of the three-dimensional knitted fabric is deteriorated at the sewing portion, and the intended cushioning property may not be obtained.

Patent Document 1 discloses a quilted laminate fabric including a three-dimensional knitted fabric expressed as a three-layer structure three-dimensional fabric so as to be integrated.
However, Patent Document 1 describes that quilt sewing is performed on the entire pad, but does not disclose any specific sewing conditions for preventing the cushion function from being lowered.

Japanese Utility Model Publication No. 06-022283

  SUMMARY OF THE INVENTION An object of the present invention is to provide a three-dimensional knitted product that is a sewn product in which a laminate using at least a part of a three-dimensional knitted fabric is joined and has excellent pressure dispersibility and a sense of unity in a laminated portion.

In order to solve the above problems, the present inventor has studied in detail a method for joining and sewing a laminated product using at least a part of a three-dimensional knitted fabric, and found that the number of joints per unit area is a major factor. As a result of further intensive studies, the present invention has been made.
That is, the present invention is as follows.

(1) A sewn product in which a laminate using at least a part of a three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabric is joined, and the three-dimensional knitted fabric is used. The three-dimensional knitted product is characterized in that the number of joints per square meter is 1 or more and 100 or less.
(2) A cushion material comprising the quilted sewing product according to (1).

Hereinafter, the present invention will be described in detail.
In the present invention, the three-dimensional knitted fabric is composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabrics. When a three-dimensional knitted fabric is knitted using a double raschel knitting machine, a double circular knitting machine, a flat knitting machine, or the like, the connecting yarn that connects the front and back knitted fabrics is 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 connecting yarn returns to the original state. Since the bending and recovery behavior of the connecting yarn generated at this time greatly affects the cushioning property of the three-dimensional knitted fabric, the monofilament having high bending rigidity is preferably used for the connecting yarn.

  Therefore, all the connecting yarns of the three-dimensional knitted fabric are preferably monofilaments, but if necessary, fibers other than monofilaments may be knitted at the time of knitting. In that case, it is preferable that the fiber other than the monofilament has a mixing ratio in the connecting yarn of 50 wt% or less, and more preferably 40 wt% or less. For example, it is preferable to knit a multifilament false twist yarn as the connecting yarn because it can reduce annoying sound generated by rubbing the monofilaments during compression.

  In the present invention, the monofilament used for the connecting yarn of the three-dimensional knitted fabric is, for example, any of polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, polyethylene terephthalate fiber, polyamide fiber, polypropylene fiber, polyvinyl chloride fiber, polyester elastomer fiber, etc. Although raw material fibers can be used, among these, polytrimethylene terephthalate fibers are preferably used for the connecting yarn because the recoverability after repeated or long-time compression becomes good.

  The fiber used for the two-layer knitted fabric of the three-dimensional knitted fabric is not particularly limited. For example, polyethylene terephthalate fiber, polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, polyester elastomer fiber, polyamide fiber, polyacrylic Synthetic fibers such as woven fibers and polypropylene fibers, natural fibers such as cotton, hemp, and wool, recycled fibers such as cupra rayon, viscose rayon, and lyocell, and other arbitrary fibers can be used.

  The cross-sectional shape of the fiber 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 Good. 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 the present invention, the three-dimensional knitted fabric can be knitted using a double raschel knitting machine, a double circular knitting machine, a flat knitting machine having a V bed, or the like having two opposite rows of needle beds. In order to obtain it, it is preferable to use a double Russell knitting machine. The gauge of the knitting machine is preferably 9 gauge to 28 gauge.

  In the present invention, the shape of the front and back surfaces of the three-dimensional knitted fabric is not particularly limited, and may be a flat one, a ridge-like one having irregularities of 0.5 mm or more, or a napped by raising treatment or the like. Good. Moreover, if the knitted fabric on the front and back sides of the three-dimensional knitted fabric is a knitted fabric having a plurality of openings such as a mesh knitted fabric such as a quadrangular or hexagonal shape, a marquette knitted fabric, etc., lightness and air permeability can be improved. The surface can be made flat to improve the touch, and the surface can be raised to obtain a good touch. In particular, in order to improve the air permeability and suppress the feeling of stuffiness with a cushion material or the like, it is preferable to use a knitted fabric having a plurality of openings on either one or both of the front and back knitted fabrics.

In the present invention, the thickness and basis weight of the three-dimensional knitted fabric can be arbitrarily set according to the purpose. The thickness is preferably 2 to 30 mm. When the thickness is in the above range, there is a sufficient amount of compression, excellent cushioning properties, and easy finishing of the three-dimensional knitted fabric. Basis weight is preferably 100 to 3000 g / m ^2, more preferably 200 to 2000 g / m ^2.

The fibers used for the front and back knitted fabrics or connecting yarns of the three-dimensional knitted fabric may be uncolored or colored.
Coloring methods include dying uncolored yarn in yarn or cheese (dyeing), coloring by mixing pigments, dyes, etc. into the stock solution before spinning (dye solution coloring), dyeing in three-dimensional knitting Although it can be colored by a printing method or the like, dyeing in a three-dimensional knitted form is difficult to maintain a three-dimensional shape or has poor processability.

Three-dimensional knitting can be finished through a process of scouring, dyeing, heat setting, etc., but the three-dimensional knitting using pre-dyed yarn or undiluted dyed yarn or three-dimensional for applications that do not require designability. In the case of knitted fabrics, it is possible to omit the scouring and dyeing process and finish the raw machine immediately by heat setting alone.
Also, during finishing set, finishing processing such as resin processing, water absorption processing, anti-static processing, antibacterial processing, water repellent processing, flame retardant processing, etc., which are usually used for fiber processing, is applied within the range that does not impair the purpose of the present invention. be able to.

  The sewn product of the present invention is a sewn product in which a laminate using at least a part of a three-dimensional knitted fabric is joined, and the number of joints per square meter of the portion where the three-dimensional knitted fabric is used is 1 or more and 100 or less. Preferably, they are 5 or more and 50 or less, More preferably, they are 10 or more and 30 or less. If it is in this range, it becomes a sewn product excellent in pressure dispersibility. However, if the number of joints exceeds 100, the pressure dispersibility is inferior, and if it is less than 1, the sense of unity of the laminated portion may not be obtained.

The number of junctions per square meter is calculated by the following formula.
Number of joints (pieces / m ² ) = (total number of joints in the sewing product) / (area of the sewing product [m ² ])
Further, the portion where the three-dimensional knitted fabric is used refers to the area of a portion where a plurality of three-dimensional knitted fabrics are laminated, or the area of the portion where a three-dimensional knitted fabric and another material are laminated. When the three-dimensional knitted fabric is used for only a part of the entire sewn product, the area of the part is referred to.

  In the present invention, the term “joining” refers to partial sewing in order to integrate the laminated product, and the sewing length of the joining portion is 2 cm or less. The sewing method is not particularly limited as long as the sewing length is 2 cm or less, and may be sewn by any method such as hand-sewing, main sewing, staggered stitching, single-ring stitching, double-ring stitching, and flat stitching. Further, the sewing may be any method such as a straight line, a curved line, or a zigzag. The position of the joining portion is not particularly limited, and may be uniformly joined within the stacked area or may be joined non-uniformly.

  Furthermore, the bonded sewn product of the present invention may be a laminate of materials mainly composed of synthetic fibers and ultrasonically sewn as long as it can be sewn with an ultrasonic sewing machine.

  In the sewn product of the present invention, a three-dimensional knitted fabric may be used at least partially, and a plurality of three-dimensional knitted fabrics may be laminated. Moreover, you may laminate | stack a solid knitted fabric and another raw material. Other materials include, for example, natural cotton, synthetic fiber cotton, or a combination of these fibers, as well as cotton obtained by appropriately compressing these fiber cottons, and synthetic resins applied to those cottons to improve compression recovery. Or foams such as urethane foam, polyethylene foam, and polystyrene, and combinations of these foams and cotton, or fibers made of thermoplastic resin or thermoplastic elastic resin, are entangled irregularly. Examples thereof include a three-dimensional structure having a thickness of about 5 to 50 mm for forming a contact point brought into contact by entanglement.

  As long as the object and effect of the present invention are not impaired, the three-dimensional knitted fabric product of the present invention is integrated by using the sewn product as a core material, covering it with other materials, partially sewing with other materials, bonding, etc. May be.

  Moreover, the outer periphery of the sewn product of the present invention may be sewn with an edge cover material. The edge cover material is not particularly limited, and may be a woven fabric, a knitted fabric, a film, or the like. The woven or knitted fabric used for the edge cover material may be a crushing process by calendering, a resin processed by urethane or acrylic resin, etc., and a film of urethane, acrylic or vinyl chloride laminated on one or both sides. May be. The shape may be any of a narrow slit, a straight cut, a bias cut, and the like. Further, it may be a narrow tape or ribbon commercially available for piping or the like. In particular, it is preferable that the edge cover material is processed in advance so as not to fray from the end portion, because the end portion of the edge cover material does not need to be folded back and the sewing portion can be finished thin.

  When monofilaments of 15 dtex or more are used in the three-dimensional knitted fabric, the end of the monofilament may penetrate the edge cover material and come out to the surface, irritate the skin, and in extreme cases, penetrate the skin. May cause scratches. In order to prevent this, it is preferable to use a piercing strength of the sewing needle as the edge cover material of 2 to 20N, more preferably 2.1N or more and 15N or less, and 2.2N or more and 10N or less. Is most preferred. If the perforation strength of the edge cover material is within the above range, the end of the monofilament will not protrude, the bending strength of the edge cover material will be appropriate, the texture will be good, and the needle penetration resistance during sewing Is easy to sew.

  The piercing strength of the sewing needle is such that the sewing needle (TV × 7 # 19 manufactured by Organ Co., Ltd.) does not move to the chuck part of Shimadzu Autograph AG-B type (manufactured by Shimadzu Corporation) Attached parallel to the vertical movement direction, the edge cover material was fixed to a disk-shaped compression jig with a pin with a diameter of 20 mm, then pierced at a speed of 50 mm / min, and the maximum stress at the time of penetration was measured three times on each side. The average value was expressed.

  The edge cover material may be sewn by a method described in, for example, the subclassification of Class 3 class 3 of JIS-L-0121.

  The three-dimensional knitted product of the present invention is excellent in pressure dispersibility, has a sense of unity, and is particularly useful as a cushioning material.

The present invention will be further described with reference to the following examples. However, the present invention is not limited to these examples. Measurement methods, evaluation methods, etc. are as follows.
(1) Thickness Conforms to the thickness measurement method of JIS-L-1018.

(2) Pressure dispersibility and sense of unity Using the sewn products and simple laminates prepared in the examples and comparative examples, a saddle bed test was conducted, and the pressure dispersibility and the sense of unity of the laminates were subjected to a sensory evaluation. Scoring was performed. The bed test was carried out by 10 persons engaged in fiber-related work, and the average score of the 10 persons was evaluated.

B) Pressure dispersibility 3 points: Almost no change in pressure dispersibility compared to mere laminate products 2 points: Slightly lower pressure dispersibility than mere laminate products 1 point: Very much compared to mere laminate products Low pressure dispersibility

B) Sense of unity 3 points: feels almost no displacement when laid down 2 points: feels slightly distorted when laid down 1 point: feels very different when laid down

(3) Surface texture of edge cover material The surface texture of the edge cover material of the quilted sewing product created in the examples and comparative examples was sensory evaluated and scored according to the following criteria. In addition, the evaluation test was performed by 10 persons engaged in fiber-related work, and the average score of the 10 persons was evaluated.

"Feel"
3 points: almost no jumping of monofilament fibers on the edge cover material surface 2 points: feels a slight jump of monofilament fibers on the edge cover material surface 1 point: I feel very much the jumping of monofilament fibers on the edge cover material surface

[Production Example 1] (Production of solid knitted fabric)
Using an 18-gauge, 5.6 mm double raschel 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 ( L5, L6), 167 decitex / 48 filament polyethylene terephthalate multifilament yarn (Asahi Kasei Fibers) Monofilament manufactured by Sensui Co., Ltd. is supplied to L1, L4, and L5 guides in a 1-in-1 out arrangement, and supplied to L2, L3, and L6 guides in a 1-out 1-in arrangement to form a three-dimensional knitted fabric of front and back meshes. . The driving was 20.7 course / 2.54 cm, and the knitting structure was as shown below.

  The raw machine of the obtained three-dimensional knitted fabric is scoured at 70 ° C., and then heat-set at 180 ° C., and the knitted fabric density on the surface of the three-dimensional knitted fabric is 27.0 course / 2.54 cm, 13.0 wal / 2.54 cm, The thickness was finished to 4.0 mm.

(Knitting organization)
L1: 4644/4244/4644/4244/4644/4222/2202/2422/2202/2422/2022/2444 /
L2: 2022/2422/2022/2422/2022/2444/4644/4244/4644/4244/4644/4222 /
L3: 6868/6644/6868/2020/6868/6644/4242/4646/4242/810810/4242/4646 /

L4: 4242/4646/4242/881010/4242/4646/6868/6644/6868/620/6868/6464 /
L5: 4446/4442/4446/4442/4446/4442/2220/2224/2220/2224/2220/2224 /
L6: 2220/2224/2220/2224/2220/2224/4446/4442/4446/4442/4446/4442 /

[Examples 1-7, Comparative Examples 1 and 2]
The three-dimensional knitted fabric obtained in Production Example 1 was cut to produce two three-dimensional knitted fabrics having a length of 200 cm and a width of 100 cm. These two three-dimensional knitted fabrics were laminated and sewn so as to be evenly spaced within the area of the laminated product with the number of joints shown in Table 1 to obtain a three-dimensional knitted product. In addition, the sewing was performed using a main sewing machine (DDL-555) manufactured by JUKI Corporation, and the sewing length was 1 cm.
The sewing conditions were as follows. Sewing needle No. 14 (manufactured by Organ Co., Ltd.), sewing thread: Polyester span No. 30, stitch length: 2.0 mm

  Table 1 shows the evaluation results of the obtained three-dimensional knitted product. As can be seen from Table 1, Examples 1 to 7 were excellent in pressure dispersibility and excellent in unity of the laminated portion. However, Comparative Example 1 was inferior in the unity of the laminated portion, and Comparative Example 2 was inferior in pressure dispersibility.

  Moreover, the edge part of the three-dimensional knitted fabric product obtained in Examples 1 to 7 and Comparative Examples 1 and 2 is covered with the PET taffeta a shown below to be 3.05 in FIG. 3 of JIS-L-0120. By using a two-needle flat stitch sewing machine (Yamato Sewing Machine Manufacturing Co., Ltd .: VEU25000 156M-8; changed to using two needles with a needle width of 5.6 mm), the symbol 309 of JIS-L-0120 is obtained. The bed pad was produced by sewing. (Sewing conditions: sewing needle No. 14 (manufactured by Organ Co., Ltd.), sewing thread: polyester span No. 30, stitch length: 2.0 mm)

The PET taffeta a used is as follows.
Warp: Polyethylene terephthalate multifilament 56 dtex / 24 filament Weft: Polyethylene terephthalate multifilament 84 dtex / 24 filament Structure: Taffeta Density after weaving and heat-set finishing: 114 vertical / 2.54 cm, horizontal 82 / 2.54 cm
Piercing strength of sewing needle: 2.45N

  The obtained bed pad was laid on a commercially available mattress, and “pressure dispersibility and unity” was evaluated. As a result, Examples 1 to 7 were bed pads with good cushioning properties, no slippage when bedded, and a good surface texture of the edge cover material. And Comparative Example 2 was a bed pad with poor physical strength dispersibility.

[Example 8]
In Example 4, a bed pad was produced in the same manner as in Example 4 except that the edge cover material was changed to the PET taffeta b shown below.
The PET taffeta b used is as follows.

Warp: Polyethylene terephthalate multifilament processed yarn 167 dtex / 48 filament Weft: Polyethylene terephthalate multifilament processed yarn 167 dtex / 48 filament Structure: Taffeta Weaving, density after heat set finish: Vertical 75 / 2.54 cm, Horizontal 61 / 2.54cm
Piercing strength of sewing needle: 1.74N

  The obtained bed pad was laid on a commercially available mattress, and “pressure dispersibility and unity” was evaluated. As a result, it was a great bed pad with good cushioning properties and no slippage when lying down. However, the monofilament jumped out on the surface of the edge cover material, which was slightly insufficient in terms of texture.

[Example 9]
A bed pad was produced in the same manner as in Example 4 except that the edge cover material was changed to the urethane coating product of the PET taffeta a in Example 4.
In addition, the urethane coating product of PET taffeta a is coated with the following compounded resin on one side of PET taffeta a with a roll coater (clearance: 150 microns, coating amount is 30 g / m ² ), and heated in 30 ° C. warm water for 5 minutes. The solvent was removed by immersion in warm water at 70 ° C. for 15 minutes to wet-coagulate the urethane. Furthermore, heat treatment was performed at 150 ° C. for 2 minutes using a pin tenter in accordance with the finishing density of PET taffeta a. The piercing strength of the sewing needle was 7.5N.

<Resin formulation>
Polyurethane resin (one-component polyurethane manufactured by Dainippon Ink and Chemicals, trade name: Crisbon 8166): 40 wt parts 4,4 diphenylmethane diisocyanate: 5 wt parts Dimethylformamide: 55 wt parts

  The obtained bed pad was laid on a commercially available mattress, and “pressure dispersibility and unity” was evaluated. As a result, it was a bed pad that had good cushioning properties, had no feeling of displacement when laid, and had a good surface texture of the edge cover material.

[Example 10]
A bed pad was produced in the same manner as in Example 4 except that the edge cover material was changed to the above PVC taffeta PVC sheet laminate.
In addition, the PVC sheet laminate product of PET taffeta a is obtained by bonding a 1 mm thick PVC sheet to a PET taffeta a with a urethane-based adhesive. The piercing strength of the sewing needle was 20.5N.

  The obtained bed pad was laid on a commercially available mattress, and “pressure dispersibility and unity” was evaluated. As a result, the cushioning property was good, and there was no misalignment when bedded. However, when sewing the edge cover material, there was a slight hindrance to the sewing due to thread breakage.

  Three-dimensional knitted garment products of the present invention are bedding, bedding such as bed pads, cushions, shoulder pads, leggers cushioning materials, supporter cushioning materials, lining materials such as warm clothing, helmet lining, human body protection pads, etc. It can be suitably used for applications such as cushioning materials, cushioning materials, and shape retaining materials that come into contact with the human body. Furthermore, it can also be used for cushion materials for vehicle seats such as automobiles, railway vehicles, airplanes, child seats, and strollers, and cushion materials for seats for furniture and offices.

Claims (2)

  A sewn product in which a laminate using at least a part of a three-dimensional knitted fabric composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabric is joined, and the three-dimensional knitted fabric is used. A three-dimensional knitted sewing product characterized in that the number of joints per square meter of the portion is 1 or more and 100 or less. A cushion material comprising the three-dimensional knitted fabric product according to claim 1.