JP2007230086A - Laminate and cushioning material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminate comprising at least three-dimensional knitting and a short fiber aggregate which is excellent in gas permeability and cushioning properties and suppresses the protrusion of short fibers from the surface and a feeling of mugginess. <P>SOLUTION: In the laminate, the three-dimensional knitting composed of knitted cloths of at least surface and back layers and connection threads connecting the knitted cloths of the two layers and the short fiber aggregate are laminated. The total cover factor (TCF)=a course cover factor (CCF)+a wale cover factor (WCF) of at least one side knitted cloth of the three-dimensional knitting is 750-1,250. When the number of the connection threads in an area of the three-dimensional knitting 2.54 cm<SP>2</SP>(6.45 cm<SP>2</SP>) is N (/6.45 cm<SP>2</SP>), the size (dtex) of the connection threads is T (g/1×10<SP>6</SP>cm), and the specific gravity of the connection threads is ρ<SB>0</SB>(g/cm<SP>3</SP>), the total cross-areal area (N*T/1×10<SP>6</SP>ρ<SB>0</SB>) of the connection threads in the area of the three-dimensional knitting 6.45 cm<SP>2</SP>is 0.01-0.4 cm<SP>2</SP>. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a laminate including a three-dimensional knitted fabric, and more specifically, a laminate composed of at least a three-dimensional knitted fabric and a short fiber assembly, which suppresses jumping of short fibers to the surface of a three-dimensional knitted fabric excellent in air permeability and cushioning properties and stuffiness. The present invention relates to a body and a cushion material using the laminate.

The three-dimensional knitted fabric has excellent breathability and cushioning properties, and is used as various cushioning materials, for example, for bed pads, bedclothes, cushions, pillows, bags, and the like. In such an application, there are cases where it is used as a cover material taking advantage of the characteristics of the three-dimensional knitted fabric, and there are cases where a short fiber aggregate is used as a core material.
However, although the three-dimensional knitted fabric has excellent air permeability, when laminated with the short fiber aggregate, the short fibers jump out on the surface of the three-dimensional knitted fabric, and further, the short fibers come off from the surface and the short fiber scraps are scattered around. There was a case.

In Patent Document 1, layered cotton fibers are bonded and fixed together with an adhesive, and the three-dimensional mesh knitted fabric is attached and fixed before the adhesive solidifies, whereby the layered cotton fibers are bonded to the three-dimensional mesh knitted fabric. A pad that does not slip out or get stuck in the mesh is disclosed.
However, in this pad, the adhesive partially adheres the layered cotton and the three-dimensional mesh knitted fabric and is not blocked in a state where there is no air permeability. Since it decreases, the feeling of stuffiness is strong and the texture may become hard.
Japanese Patent Publication No. 5-27901

  An object of the present invention is to provide a laminate composed of at least a three-dimensional knitted fabric and a short fiber assembly, which makes use of the breathability and cushioning properties of the three-dimensional knitted fabric and suppresses the short fibers from jumping out and stuffy. It is.

  In order to solve the above-mentioned problems, the present inventor has studied in detail the fiber material, structure, etc. of the three-dimensional knitted fabric. It has been determined that a significant contribution has been made and the present invention has been completed.

That is, the invention claimed in the present application is as follows.
(1) A laminate in which a three-dimensional knitted fabric composed of at least two front and back knitted fabrics and a connecting yarn connecting the two knitted fabrics and a short fiber assembly are laminated, and at least one side of the three-dimensional knitted fabric The total cover factor (TCF) of the knitted fabric is 750 to 1250, and the number of connecting yarns in the area of 2.54 cm square (6.45 cm ² ) is N (pieces / 6.45 cm ² ). When the fineness (dtex) of the connecting yarn is T (g / 1 × 10 ⁶ cm) and the specific gravity of the connecting yarn is ρ ₀ (g / cm ³ ), the connecting yarn is in the area of a solid knitted fabric 6.45 cm ^2. A total cross-sectional area (N · T / 1 × 10 ⁶ · ρ ₀ ) is 0.01 to _0.4 cm ² .
Total Cover Factor (TCF) = Course Cover Factor (CCF) + Wail Cover Factor (WCF)
However, course cover factor (CCF) = (number of courses; book / 2.54 cm) × (thickness of yarn constituting one side of knitted fabric; fineness (dtex)) ^1/2
Wale cover factor (WCF) = (number of wales; number / 2.54 cm) × (thickness of yarn constituting knitted fabric on one side; fineness (dtex)) ^1/2

(2) The laminate according to (1), wherein the laminate is integrated by quilting.
(3) The laminate according to (2), wherein the laminate has a quilting sewing length ratio of 0.005 or more and 1 or less.
Quilted sewing length ratio = total sewing length of the sewing product (cm) / area in which the three-dimensional knitted fabric was used in the sewing product (cm ² )
(4) The laminate according to any one of (1) to (3), wherein an outer periphery of the laminate is sewn with an edge cover material.
(5) A cushion material using the laminate according to any one of (1) to (4).

  According to the present invention, it is possible to obtain a laminate that is excellent in air permeability and cushioning properties, and that suppresses the short fibers from jumping out to the surface of the three-dimensional knitted fabric, and the feeling of stuffiness, and this laminate is particularly excellent when used as a cushioning material. Show the effect.

Hereinafter, the present invention will be described in detail.
The present invention relates to a laminate in which a three-dimensional knitted fabric composed of at least two front and back knitted fabrics and connecting yarns connecting the two knitted fabrics and a short fiber assembly are laminated. The short fiber aggregate referred to here includes any one in which short fibers are aggregated in a three-dimensional shape. The short fiber material is not particularly limited, and synthetic fiber, natural fiber, regenerated fiber, and a mixture thereof may be used. In addition, the aggregate is not particularly limited as long as short fibers are assembled, for example, those obtained by simply collecting short fibers into a mass, those obtained by collecting short fibers and compressing the mass, Examples include those in which short fibers are formed into a sheet shape, such as felt, and those in which short fibers are entangled with a needle or water pressure.

  It is important that the three-dimensional knitted fabric of the present invention is composed of two layers of front and back knitted fabrics and a connecting yarn that connects 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 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 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 the monofilaments may be knitted during knitting. The fibers other than the monofilament in that case preferably have a weight mixing ratio in the connecting yarn of 50% or less, more preferably 40% or less. For example, it is preferable to knit multi-filament false-twisted yarn because it can reduce annoying sound that occurs when monofilaments rub against each other during compression.

In the three-dimensional knitted fabric of the present invention, it is important that the total cover factor (TCF) of at least one side knitted fabric of the three-dimensional knitted fabric is 750 to 1250, preferably 800 to 1200, more preferably 850 to 1150, particularly preferably 950 to 950. 1100. When the total cover factor is less than 750, the short fibers jump out of the laminated short fiber aggregate to the surface of the three-dimensional knitted fabric cannot be suppressed, and when it is 1250 or more, sufficient air permeability cannot be obtained and the texture of the three-dimensional knitted fabric is inferior. It will be a thing.
Here, the total cover factor (TCF) is calculated by the following equation.

Total Cover Factor (TCF) = Course Cover Factor (CCF) + Wail Cover Factor (WCF)
However, course cover factor (CCF) = (number of courses; book / 2.54 cm) × (thickness of yarn constituting one side of knitted fabric; fineness (dtex)) ^1/2
Wale cover factor (WCF) = (number of wales; number / 2.54 cm) × (thickness of yarn constituting knitted fabric on one side; fineness (dtex)) ^1/2
Note that the thickness of the yarn constituting the knitted fabric of the surface refers to the thickness of the yarn constituting the stitches existing in the area of the knitted fabric 2.54cm square surface (6.45 cm ^2). For example, when two front yarns are supplied to the same needle from two halves to form one stitch, the total thickness of the two front yarns is the total thickness, and the connecting yarns that connect the front and back surfaces Is excluded.

When the thicknesses of the yarns constituting the stitches are different, first, the total number (n) of the stitches existing in the surface area of 2.54 cm square (6.45 cm ² ) and the yarns constituting each stitch. The thickness (D1, D2, D3,..., Dn; dtex) is measured. Next, the total thickness (D1 + D2 + D3 +... Dn; dtex) of the yarns constituting each stitch is divided by the total number (n) of the stitches. The thickness of the yarn (fineness) may be measured in accordance with the apparent fineness measurement of yarn according to JIS-L-1018, but it is difficult to take out the yarn from the knitted fabric like a warp knitted fabric. The fineness may be obtained by calculation from the average diameter and specific gravity of the fiber.

In the present invention, the course cover factor (CCF) is preferably 400 to 800, particularly preferably 450 to 750, more preferably 500 to 700, and the wale cover factor (WCF) is preferably 250 to 550, particularly 300 to 500. Is preferable, and 350 to 450 is more preferable.
In the three-dimensional knitted fabric of the present invention, the total cover factor (TCF) of one side knitted fabric needs to be 750 to 1250, but the total cover factor of the other side knitted fabric is not limited to this.

In the three-dimensional knitted fabric of the present invention, the number of connecting yarns in an area of 2.54 cm square (6.45 cm ² ) is N (pieces / 6.45 cm ² ), and the fineness (dtex) of the connecting yarns is T (g / 1 × 10 ⁶ cm), when the specific gravity of the connecting yarn is ρ ₀ (g / cm ³ ), the total cross-sectional area of the connecting yarn in the area of the solid knitted fabric 6.45 cm ² (N · T / 1 × 10 ⁶ · ρ ₀ ) must be 0.01 to _0.4 cm ² . This range is preferably 0.01~0.3cm ^2, more preferably 0.03~0.25cm ^2. When the total cross-sectional area of the connecting yarn is less than 0.01 cm ² , the compressive stress becomes very low and the cushioning property cannot be obtained, and when it is repeatedly compressed, the thickness is greatly reduced. On the other hand, if it exceeds 0.4 cm ² , the compressive stress becomes extremely high, so that it hardly undergoes compression deformation and cushioning properties cannot be obtained. The fineness of the connecting yarn may be measured in accordance with the apparent fineness measurement of yarn according to JIS-L-1018. If it is difficult to take out the yarn from the knitted fabric like a warp knitted fabric, the average of the fibers What is necessary is just to obtain | require the fineness by calculation from a diameter and specific gravity.

  The three-dimensional knitted fabric of the present invention preferably has a compressive stress of 10 to 1000 N at 50% compression, more preferably 20 to 400 N, and most preferably 30 to 350 N. When the compression elastic modulus is less than 10 N, a sufficient gap cannot be obtained between the front and back tissues when used as a cushion material. On the other hand, if it exceeds 1000 N, a gap is ensured between the front and back tissues, but the cushioning property may not be obtained because it is hardly compressed in the thickness direction.

The air permeability of the three-dimensional knitted fabric of the present invention is preferably 30 cm ³ / cm ² · sec or more, more preferably 50 cm ³ / cm ² · sec or more and 500 cm ³ / cm ² · sec or less, more preferably 80 cm ³ / cm. ^{It is 2} · sec or more and 300 cm ³ / cm ² · sec or less. Within this range, the air permeability of the laminate with the short fiber aggregate is ensured.

  Monofilaments preferably used for the connecting yarn of the three-dimensional knitted fabric of the present invention are polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, polyethylene terephthalate fiber, polyamide fiber, polypropylene fiber, polyvinyl chloride fiber, saran fiber, polylactic acid, polycaprolactan Fibers of any material such as polybutylene succinates, polyethylene succinates, aliphatic polyesters such as polyglycolic acid, copolymers of the aliphatic polyesters and aromatic polyesters, polyester elastomer fibers, etc. However, it is preferable to use the polytrimethylene terephthalate fiber for the connecting yarn because the recoverability after repeated or long-time compression becomes good.

  The fibers used for the two-layer knitted fabric of the three-dimensional knitted fabric are not particularly limited, and are polyethylene terephthalate fiber, polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, saran fiber, polylactic acid, polycaprolactan, polybutylene. Aliphatic polyester such as succinate, polyethylene succinate, polyglycolic acid, copolymer of aliphatic polyester and aromatic polyester, polyester elastomer fiber, polyamide fiber, polyacrylic fiber, polypropylene fiber, etc. Synthetic 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.

  The three-dimensional knitted fabric of the present invention can be knitted with a double raschel knitting machine having two rows of needle beds, a double circular knitting machine, a flat knitting machine with a V bed, etc., but in order to obtain a three-dimensional knitted fabric with good dimensional stability. It is preferable to use a double Russell knitting machine. The gauge of the knitting machine is preferably 9 gauge to 30 gauge.

  The shape of the front and back surfaces of the three-dimensional knitted fabric of the present invention is not particularly limited as long as the object of the present invention can be achieved, and is flat, or has a rugged shape of 0.5 mm or more, raised by raising treatment, etc. However, 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 and a marquette knitted fabric such as a square and a hexagon. Can be made. The surface can be made flat to improve the touch. By raising the surface, a material having a good touch can be obtained.

The thickness and basis weight of the three-dimensional knitted fabric of the present invention can be arbitrarily set according to the purpose. The thickness is preferably 2 to 30 mm, more preferably 2.5 to 15 mm. When the thickness is less than 2 mm, the amount of compression is small and the cushioning property may be inferior, and when it exceeds 30 mm, it may be difficult to finish 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 of the present invention may be uncolored or 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 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.

As a finishing method of three-dimensional knitted fabric, the raw machine can be finished through processes such as scouring, dyeing, heat setting, etc., but if design properties are not required as a three-dimensional knitted fabric or use using pre-dyed yarn or stock solution colored yarn, It is also possible to finish the raw machine immediately by heat setting without the scouring and dyeing process.
In addition, finishing processing such as resin processing, water absorption processing, antistatic processing, antibacterial processing, water repellent processing, and flame retardant processing, which are usually used for fiber processing, can be applied as long as the purpose of the present invention is not impaired during finishing set. .

In the laminate of the present invention, it is important that a three-dimensional knitted fabric and a short fiber assembly are laminated. When the three-dimensional knitted fabric is (A) and the short fiber assembly is (B), any one of ABA, ABABA, and ABBA may be used.
Moreover, as long as AB is laminated | stacked, the other side of B may be a common cloth which is not a three-dimensional knitted fabric, such as a woven fabric and a knitted fabric.
Moreover, if the effect of the present invention can be achieved, foams such as urethane foam, polyethylene foam, and polystyrene, and fibers made of thermoplastic resin or thermoplastic elastic resin are irregularly entangled with each other to form a contact point in contact by entanglement. Three-dimensional structures having a thickness of about 5 to 50 mm may be stacked.

  It is preferable that the laminated body of the present invention is quilted and sewn because a solid knitted fabric and a short fiber assembly can be integrated. When quilting the laminate, the quilting sewing length ratio is preferably 0.005 or more, or 1 or less, more preferably 0.01 or more, or 0.5 or less, and still more preferably 0.01 or more. Or 0.1 or less. If it is in this range, the cushioning properties and the soft feeling of the laminate will be compatible.

The quilting sewing length ratio is expressed by the following formula.
Quilted sewing length ratio = total sewing length of the sewing product (cm) / area in which the three-dimensional knitted fabric was used in the sewing product (cm ² )
Here, the area where the three-dimensional knitted fabric is used refers to the area of a laminate of a plurality of three-dimensional knitted fabrics or a laminate of a three-dimensional knitted fabric and another material. When a solid knitted fabric is used for only a part of the entire sewn product, that part is shown. Moreover, when the circumference | surroundings of a solid knitted fabric are covered with the edge cover material, the area except an edge cover material is shown.

Sewing length refers to the sum of the lengths sewn regardless of whether they are continuous or discontinuous, and the sewing method is not particularly limited, and includes hand stitching, main stitching, staggered stitching, single ring stitching, double ring stitching, flat stitching The sewing may be performed by any method of sewing. The sewing may be any method such as a straight line, a curved line, or a zigzag. Further, the quilting pattern also includes any ones such as those obtained by sewing only one piece vertically, horizontally or diagonally, those obtained by sewing a plurality of pieces regardless of parallel or non-parallel, and those obtained by sewing in a lattice pattern.
Furthermore, the laminated body used in the present invention may be ultrasonically sewn as long as the laminated body used for the quilting sewing is made of a synthetic fiber and can be quilted by an ultrasonic sewing machine.

  It is preferable that the outer periphery of the laminate of the present invention is 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. For a woven or knitted fabric, a crushing process by calendar processing, a resin processing by urethane or acrylic resin, urethane, acrylic, or vinyl chloride is used. Such a film may be laminated on one side or both sides. Further, the shape may be any of a slit, a straight cut, and a bias cut. 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 made thin.

  In addition, when a monofilament of 15 dtex or more is used in the three-dimensional knitted fabric of the present invention, the edge knitted material may penetrate and come out to the surface. In such a case, it is preferable to use the edge cover material having a piercing strength of the sewing needle in the range of 2N to 20N, more preferably 2.1N to 15N, and most preferably 2.2N. Above, it is below 10N. If it is less than 2N, monofilaments may jump to the surface of the edge cover material, irritate the skin, and in extreme cases, the skin may penetrate and cause a wound. On the other hand, if it exceeds 20N, the bending strength of the edge cover material is increased and the texture is not only impaired, but also the needle penetration resistance is increased during sewing, and normal sewing becomes difficult. The piercing strength of the sewing needle is measured by moving the chuck part up and down so that the sewing needle (Organ Corporation TV x 7 # 19) does not move to the chuck part of Shimadzu Autograph AG B type (manufactured by Shimadzu Corporation). Attached parallel to the direction, the edge cover material was fixed to a disk-shaped compression jig with a pin with a diameter of 20 mm, 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 is obtained.

  The edge cover material may be sewn by the method described in, for example, JIS-L-0121, Fig. 3, Class 3 subcategory, and in the length direction in which the stitches visible from the front and back of the edge cover are sewn. Therefore, the position portion of the needle may be appropriately changed so that the right-angle sewing width is within the range of the present invention. If the edge cover material is processed in advance so as not to fray from the end portion, the portion to be sewn may not be folded.

The present invention will be specifically described with reference to examples.
(1) Thickness measurement It measured based on the measuring method of the thickness of JIS-L-1018.
(2) Breathability Three-dimensional knitted fabrics and laminates were measured according to the JIS-L-1018 breathability (using Frazier type tester) measurement method.
(3) Evaluation of the short fiber jumping to the surface of the three-dimensional knitted fabric of the laminate, the feeling of stuffiness, the sense of unity, and the edge cover material surface condition

  The laminates prepared in Examples and Comparative Examples were laid on a Paramount Supermattress (registered trademark) manufactured by Paramount, and the anchorage test was conducted for 10 days. Then, the sense of unity and the edge cover material surface state were evaluated, and scored based on the following judgment in sensory evaluation. In addition, the bed test was evaluated by 10 persons engaged in fiber-related matters, and the average score was evaluated.

"Short fiber jumping out"
3 points: Short fibers jump out to the surface of the three-dimensional knitted fabric.
2 points: Some short fibers jump out to the surface of the solid knitted fabric.
1 point: The short fiber jumps out to the surface of the solid knitted fabric.

"Steaminess"
3 points: There is almost no stuffiness when bedridden.
2 points: Slightly stuffy when bedridden.
1 point: A feeling of stuffiness is felt very much when bedded.

"sense of unity"
3 points: Almost no slippage when feeling bed.
2 points: A slight misalignment is felt when the user is laid down.
1 point: A feeling of displacement is very felt when the user is laid down.

"Edge cover material surface condition"
3 points: Almost no protrusion of monofilament fibers on the edge cover material surface.
2 points: Slightly feel the monofilament fiber jumping out on the edge cover material surface.
1 point: Monofilament fibers jump out very much on the edge cover material surface.

[Example 1]
Using 22 gauge, 4.2 mm double raschel knitting machine equipped with 6 rivets, 167 dtex / 48 fW cross section of polyethylene terephthalate fiber with 2 creases (L1, L2) forming the surface knitted fabric False twisted yarn (made by Asahi Kasei Fibers Co., Ltd., trademark “Technofine” false twisted yarn) is supplied in an all-in arrangement, and the two ridges (L5, L6) that form the back knitted fabric are also used. The same false twisted yarn is supplied in an array of L5 3 in 1 out, L6 (1 in) 1 out 3 in, and a 56 dtex nylon 66 fiber monofilament yarn is all-in on the end of L3 forming the connecting yarn. A solid knitting machine having a surface knitted fabric density of 33.3 courses / 2.54 cm and 24.8 wales / 2.54 cm was knitted with the following structure.

L1: 1211/1011
L2: 1011/2322 /
L3: 0110/1001 /
L5: 2210/1112/1110/1121/2234/3332/3334/3323 /
L6: 2234/3332/3334/3323/2210/1112/1110/1121 /

The obtained raw machine was scoured according to a conventional method, and then heat-set by dry heat to obtain a three-dimensional knitted fabric having a surface knitted fabric having a flat structure and a back knitted fabric having a mesh structure thickness of 3.5 mm.
The surface knitted fabric density of the obtained three-dimensional knitted fabric was 35.0 course / 2.54 cm, 22.2 wal / 2.54 cm, and other knitted fabric properties are shown in Table 1.
After layered cotton (300 g / m ² ) made of the obtained three-dimensional knitted fabric and cotton yarn is cut into 1 m × 2 m each, it is laminated with two three-dimensional knitted fabrics so that the layered cotton is sandwiched, and the long side is 4 etc. in the short side and the square. Quilted sewing was performed as shown. In addition, the main sewing was performed using a main sewing machine (DDL-555) manufactured by JUKI Corporation. 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
After quilting sewing, the edge is covered with the edge cover material PET taffeta a to be 3.05 in JIS-L-0120 Attached Figure 3 and a two-needle flat stitch sewing machine (VEU25000 156M-8 manufactured by Yamato Sewing Machine Co., Ltd.) Using a needle width of 5.6 mm and changing to using two needles), a laminated body was created by sewing so as to obtain a display symbol 309 of JIS-L-0120. (Sewing conditions: sewing needle No. 14 (manufactured by Organ Co., Ltd.), sewing thread: polyester span No. 30, stitch length: 2.0 mm)
The following PET taffeta a was used.

Warp: Polyethylene terephthalate multifilament 56 dtex / 24 filament Weft: Polyethylene terephthalate multifilament 84 dtex / 24 filament Tissue: Taffeta Density after weaving and heat setting: 114 vertical / 2.54 cm, horizontal 82 / 2.54 cm
Piercing strength of sewing needle: 2.45N
The evaluation results of the obtained laminate are shown in Table 1. The laminate of the present invention is excellent in air permeability, does not jump out to the surface of the three-dimensional knitted fabric of short fibers, has a feeling of stuffiness, unity, and edge cover material surface. The condition was also good and very good. The texture of the laminate and the edge cover material was also flexible and good.

[Examples 2 to 4, Comparative Example 1]
In Example 1, a three-dimensional knitted fabric having a different total cover factor (TCF) of the surface knitted fabric was finished by changing the gauge of the double raschel knitting machine, the density design of the green machine, and the width at the time of finishing. The obtained knitted fabric properties are shown in Table 1.
A laminate was prepared from the obtained three-dimensional knitted fabric in the same manner as in Example 1.
The evaluation results of the laminates are shown in Table 1. The laminates of Examples 2 to 4 are excellent in air permeability, do not jump out to the surface of the three-dimensional knitted fabric of short fibers, and have a feeling of stuffiness, a sense of unity, and an edge cover material surface state. The texture of the laminate and the edge cover material was also flexible and extremely excellent. On the other hand, the laminate of Comparative Example 1 was inferior in evaluation of jumping out of short fibers because the total cover factor of the three-dimensional knitted fabric was small.

[Comparative Example 2]
In Example 1, the 56 dtex nylon 66 fiber monofilament yarn of L3 forming the connecting yarn was changed to 220 dtex nylon 66 fiber monofilament yarn, and as shown in Table 1, the gauge of the double raschel knitting machine, the density design of the green machine, and the width at the finish A different three-dimensional knitting was finished by changing the stock. The obtained knitted fabric properties are shown in Table 1.
A laminate was prepared from the obtained three-dimensional knitted fabric in the same manner as in Example 1. Although the evaluation results are shown in Table 1, the obtained laminate has a poor evaluation of stuffiness, the total cross-sectional area of the connecting yarn is too large, the cushion is inferior, the texture of the laminate itself is hard, Etc. are likely to occur.

[Examples 5 and 6]
A laminated body was produced in the same manner as in Example 1 except that quilting sewing was performed so that the sewing length and number shown in Table 1 were evenly spaced on each side.
The evaluation results of the laminates are shown in Table 1. The laminates of Examples 5 and 6 are excellent in air permeability, do not jump out to the surface of the three-dimensional knitted fabric of short fibers, have a good feeling of stuffiness, and the edge cover material surface state is also good. Although the laminate of Example 5 was somewhat lacking in the sense of unity of the laminate, and the laminate of Example 6 had a large proportion of quilted sewing length, the texture of the laminate was It was hard and slightly inferior in cushioning properties.

[Example 7]
A laminate was prepared in the same manner as in Example 1 except that the edge cover material was changed to PET taffeta b.
The following PET taffeta b was used.
Warp: Polyethylene terephthalate multifilament processed yarn 167 dtex / 48 filament Weft: Same as above Structure: Taffeta Density after weaving and heat setting: 75 vertical / 2.54 cm, 61 horizontal / 2.54 cm
Piercing strength of sewing needle: 1.74N
Although the evaluation results are shown in Table 1, the obtained laminate was excellent in breathability, did not jump out to the surface of the three-dimensional knitted fabric of short fibers, and was very excellent in stuffiness and unity. The monofilament of the connecting yarn penetrated from the cover material, and the surface state was inferior.

[Example 8]
A laminate was prepared in the same manner as in Example 1 except that the edge cover material was changed to a polyvinyl chloride sheet laminate of PET taffeta a.
In addition, the polyvinyl chloride sheet laminate product of PET taffeta a is obtained by laminating the sheet of 1 mm thickness on PET taffeta a with a urethane-based adhesive.
Piercing strength of sewing needle: 20.5N
The evaluation results are shown in Table 1. The obtained laminate was excellent in air permeability, without jumping out of the short fibers to the surface of the three-dimensional knitted fabric, and extremely sultry, unity, and the surface state of the edge cover material were also excellent. Although it was a thing, the thread-cut texture was hard by sewing of the edge cover material.

[Comparative Example 3]
In Example 1, 100 g / m ² of ethylene vinyl acetate powder was uniformly spread on the front and back surfaces of layered cotton, and the three-dimensional knitted fabric of Example 1 was adhered to the front and back surfaces with a hot roll at 80 ° C., and quilting sewing was not performed. 1 was sewn with an edge cover material to obtain a laminate.
Although the evaluation result is shown in Table 1, since the layered cotton and the three-dimensional knitted fabric were bonded, the evaluation of stuffiness was inferior and the texture of the layered product was hard.

  The laminate of the present invention is used for bedding, bedding such as bed pads, cushions, shoulder pads, leggers cushioning materials, supporter cushioning materials, lining materials such as warm clothing, helmet linings, human body protection pads, etc. It can be suitably used for applications such as contact cushioning material, cushioning material, and shape retaining material. Furthermore, it can also be used for cushioning materials for vehicle seats such as automobiles, railway vehicles, airplanes, child seats, strollers, and cushioning materials for seats used for furniture and offices.

Claims (5)

A laminate in which a three-dimensional knitted fabric composed of at least two front and back knitted fabrics and a connecting yarn that connects the two knitted fabrics and a short fiber assembly are laminated, and the at least one-side knitted fabric of the three-dimensional knitted fabric The total cover factor (TCF) is 750 to 1250, and the number of connecting yarns in the area of 2.54 cm square (6.45 cm ² ) of the three-dimensional knitted fabric is N (6 / 4.45 cm ² ). When the fineness (dtex) is T (g / 1 × 10 ⁶ cm) and the specific gravity of the connecting yarn is ρ ₀ (g / cm ³ ), the total cut of the connecting yarn in the area of the solid knitted fabric 6.45 cm ² A laminate having an area (N · T / 1 × 10 ⁶ · ρ ₀ ) of 0.01 to _0.4 cm ² .
Total Cover Factor (TCF) = Course Cover Factor (CCF) + Wail Cover Factor (WCF)
However, course cover factor (CCF) = (number of courses; book / 2.54 cm) × (thickness of yarn constituting one side of knitted fabric; fineness (dtex)) ^1/2
Wale cover factor (WCF) = (number of wales; number / 2.54 cm) × (thickness of yarn constituting knitted fabric on one side; fineness (dtex)) ^1/2   The laminate according to claim 1, wherein the laminate is integrated by quilting. The laminate according to claim 2, wherein the quilting sewing length ratio of the laminate is 0.005 or more and 1 or less.
Quilted sewing length ratio = total sewing length of the sewing product (cm) / area in which the three-dimensional knitted fabric was used in the sewing product (cm ² )   The laminate according to any one of claims 1 to 3, wherein an outer periphery of the laminate is sewn with an edge cover material.   The cushion material using the laminated body in any one of Claims 1-4.