JP2007289396A - Cushioning material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushioning material having a good appearance which is utilized especially for bedding such as a bed pad, a floor cushion, and a laying mat as the cushioning material for which the outer periphery of a three-dimensionally knitted article has been cover-processed with an edge section cover material, wherein the cushioning material can normally be washed by a washing machine for home use, can prevent the edge section from shape-collapsing after being dried and has a little appearance change, and can prevent the edge section from shape-collapsing after being dried even when a high-temperature washing is performed by a tumbler type washing machine, and has a little appearance change. <P>SOLUTION: A cushion member consists of lamination of one sheet or a plurality of sheets of the three-dimensionally knitted article consisting of two layers of front and rear knitted fabrics and a connecting yarn for connecting the two layers of the knitted fabrics. The outer periphery of the cushion member is covered with the edge section cover material for this cushioning material. A difference (X1) in washing shrinkage ratio at the time of washing at 40°C by a washing machine for home use is 0±5.0 for both in the vertical and lateral directions for the cushioning material. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a cushioning material in which the outer periphery of a three-dimensional knitted fabric is coated with an edge cover material, and is used in particular for bedding such as a bed pad, a cushion, a mat, etc., and can be normally washed by a household washing machine and dried. The present invention relates to a cushion material that prevents edge shape collapse and changes in appearance, and a cushion material that prevents edge shape deformation and changes in appearance after drying even in high-temperature washing using a tumbler-type washing machine.

In recent years, three-dimensional knitted fabrics have been devised and put to practical use as a breathable cushioning material that replaces polyurethane foam due to its unique structure, such as seats for vehicles and furniture chairs, as well as cushions and bedding materials. .
Cushion materials constructed by coating the outer periphery of these three-dimensional knitted fabrics with edge cover materials are superior to conventional foamed urethane and cushion materials filled with cotton or hard cotton because they are excellent in dewaterability and quick drying after washing. Washing with water or a washing machine for home use was possible. However, since the relationship between the washing shrinkage rate of the three-dimensional knitted fabric and the washing shrinkage rate of the edge cover material is not taken into consideration, the poor appearance due to the appearance change (out of shape) around the edge after washing and drying cannot be resolved. It was.

For example, Patent Document 1 discloses a cushion material obtained by sewing an outer peripheral portion of a three-dimensional knitted fabric with an edge cover material. However, the cushion material in which the outer periphery of the three-dimensional knitted fabric is covered with an edge member by sewing or the like has a problem in that when the clothes are washed at home and dried, the appearance around the edge changes, and the appearance is deteriorated. Moreover, high temperature washing is indispensable depending on the use to be used, and in the case of high temperature washing, the shape of the periphery around the edge portion was particularly remarkable. The purpose of the edge member in Patent Document 1 is to prevent protrusions (monofilament cut ends) from protruding from the edge cover material, to prevent skin irritation and extreme stinging, and various washing There is no description or even suggestion of a method for preventing the appearance change (out of shape, etc.).
JP 2005-124981 A

  The present invention is used as a cushioning material in which the outer periphery of a three-dimensional knitted fabric is coated with an edge cover material, particularly for bedding such as a bed pad, a cushion, a mat, etc., and can be normally washed by a household washing machine. Therefore, it is possible to provide a cushioning material that prevents edge-shaped collapse after drying and has little appearance change, and a cushioning material that prevents edge-shaped collapse after drying and does not change appearance even when washed at high temperature by a tumbler-type washing machine. With the goal.

In order to solve the above problems, the inventor has intensively studied the relationship between the laundry shrinkage rate of the three-dimensional knitted fabric and the laundry shrinkage rate of the edge cover material and the combination of the cushion members, and as a result, the present invention has been completed.
That is, the present invention is as follows.
(1) Cushion material in which the outer periphery of a cushion member obtained by laminating one or a plurality of three-dimensional knitted fabrics composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabrics is covered with an edge cover material The cushioning material is characterized in that the difference in washing shrinkage (X1) when washing at 40 ° C. by a household washing machine is 0 ± 5.0 in both the vertical and horizontal directions.
Here, the laundry shrinkage rate difference (X1) = the laundry shrinkage rate of the three-dimensional knitted fabric (A1) −the laundry shrinkage rate (B1) of the edge cover material.
(2) The cushioning material according to (1) above, wherein the difference in washing shrinkage (X2) during high temperature washing at 80 ° C. by a tumbler type washing machine is 0 ± 5.0 in both the vertical and horizontal directions.
Here, the laundry shrinkage rate difference (X2) = the laundry shrinkage rate of the three-dimensional knitted fabric (A2) −the laundry shrinkage rate of the edge cover material (B2).
(3) The cushion material according to (1) or (2) above, wherein the connecting yarn of the three-dimensional knitted fabric is a monofilament of 10 to 1500 dtex.

  The present invention is a cushioning material that can be washed normally by a household washing machine, and prevents edge-shaped collapse after drying and changes in appearance, particularly when used for bedding such as bed pads, cushions, and mats. In addition, it becomes a good-looking cushioning material that prevents edge-shaped collapse after drying and does not change appearance even in high-temperature washing with a tumbler-type washing machine.

The present invention will be specifically described below.
The cushion material of the present invention has a laundry shrinkage rate difference (X1) = (A1) − (B1) between the laundry shrinkage rate (A1) of the three-dimensional knitted fabric used as the cushion member and the laundry shrinkage rate (B1) of the edge cover material. It is important to configure with a combination of 0 ± 5.0 in both the vertical and horizontal directions. Here, A1 and B1 indicate washing shrinkage rates at the time of 40 ° C. washing by a household washing machine described later. More specifically, the vertical difference in the laundry shrinkage rate of the cushion material (X1 _TATE ) = the vertical laundry shrinkage rate of the three-dimensional knitted fabric constituting the cushion material (A1 _TATE ) _-the vertical wash shrinkage rate of the edge cover material constituting the cushion material ( B1 _TATE ) and a difference in washing shrinkage rate in the horizontal direction of the cushion material (X1 _YOKO ) = horizontal washing shrinkage rate of the three-dimensional knitted fabric constituting the cushion material (A1 _YOKO ) _—the lateral washing shrinkage of the edge cover material constituting the cushion material Both ratios (B1 _YOKO ) may be in the range of 0 ± 5. If the difference in washing shrinkage rate is outside the range of 0 ± 5.0, the shrinkage difference between the three-dimensional knitted fabric and the cover material will increase, so that the outer shape of the outer periphery of the cushioning material will be deformed and the appearance will be poor. Significantly detracts from value.

In order to achieve the present invention, various three-dimensional knitted fabrics and edge cover materials are individually measured in the warp and transverse direction in each direction, and the members and the directions to be used are appropriately selected so that they are within the above ranges. good.
In addition, even if the cushion member is a three-dimensional knitted fabric laminate, the difference in washing shrinkage (X1) between each three-dimensional knitted fabric and the edge cover material is in the range of 0 ± 5.0 in both the vertical and horizontal directions. It is sufficient that the shape of the cushion material is not noticeable even after washing for home use. Preferably, the difference in washing shrinkage rate (X1) is 0 ± 3.5 in both the vertical and horizontal directions, more preferably 0 ± 3.0, and the difference in the washing shrinkage rate (X1) is the least noticeable. It is most preferable that the horizontal direction is 0, that is, the case where the cushion member and the edge cover material have the same washing shrinkage rate.

  In the cushion material of the present invention, the difference (X2) = (A2) − (B2) in the laundry shrinkage rate between the 80 ° C. washing shrinkage rate (A2) of the three-dimensional knitted fabric and the 80 ° C. washing shrinkage rate (B2) of the edge cover material. A combination of 0 ± 5.0 in both the vertical and horizontal directions is preferable because the deformation around the cushion material due to high-temperature washing becomes inconspicuous.

  However, even if the difference in laundry shrinkage rate is within the range of 0 ± 5.0, for example, the laundry shrinkage rate (A1) of the three-dimensional knitted fabric and the laundry shrinkage rate (B1) of the edge cover material are both + 5.0%. Since the overall cushion size of the cushion material exceeds the size after washing and drying, the appearance of the product after washing and drying will change if the size of the product is reduced in consideration of the shrinkage rate and is made to the specified standard size by steaming. Will not occur, and the product value will not be impaired. Although it does not specifically limit as a steam processing method, The processing temperature of 80-180 degreeC is possible, and what can be selected according to the kind of fiber raw material to be used is preferable.

Each three-dimensional knitted fabric used for the cushion material of the present invention is constituted by a connecting yarn that connects the front and back knitted fabrics and the front and back knitted fabrics. The solid knitted fabric can be knitted by a double raschel machine having two rows of needle rows, a double circular knitting machine, a flat knitting machine having a V bed, or the like. Is preferably used. The knitting machine gauge is preferably 7 to 32 gauge.
The thickness of the three-dimensional knitted fabric is preferably in the range of 1.5 to 25 mm, and preferably 3.0 to 20 mm in order to obtain an appropriate cushioning property. When the thickness is less than 1.5 mm, the cushioning property is inferior, and furthermore, sufficient air permeability cannot be obtained. On the other hand, if the thickness exceeds 25 mm, the productivity and finishing of the knitted fabric become difficult.

The ground structure forming the front and back knitted fabrics of the three-dimensional knitted fabric is not particularly limited, and a flat knitted fabric, a knitted fabric having a plurality of openings such as a mesh knitted fabric, a knitted fabric having irregularities in a hook shape, It may be a knitted fabric having napping in a raising process or the like. Further, the front and back may be the same knitting structure or a combination of different structures.
The type of fiber used for the front and back knitted surfaces of the three-dimensional knitted fabric is not particularly limited. For example, synthetic fibers such as polyester, polyamide and polyacrylonitrile, regenerated cellulose fibers such as cupra and rayon, wool, cotton Natural fibers and the like. In addition, the cross-sectional shape of the fiber is round, triangular, L-shaped, T-shaped, Y-shaped, W-shaped, four-leaf type, eight-leaf type, flat, dog-bone type, etc., multi-leaf type, It may be hollow or irregular.

  The connecting yarn that connects the front and back knitted surfaces of the three-dimensional knitted fabric does not limit the fiber type, single yarn fineness, cross-sectional shape, etc., but is preferably a synthetic fiber monofilament. The single yarn fineness is preferably 10 to 1500 dtex, more preferably 20 to 1000 dtex. A plurality of monofilaments may be twisted yarn, monofilament and multifilament composite yarn, or knitted yarn within a predetermined fineness range. In order to maintain the space between the front and back knitted surfaces of the three-dimensional knitted fabric and improve air permeability and cushioning properties, it is preferable to use 10 to 1500 dtex synthetic fiber monofilament at least 30 wt% or more. If the single yarn fineness of the connecting yarn is 10 dtex or more, it is easy to maintain the space between the front and back knitted surfaces of the three-dimensional knitted fabric due to the bending rigidity of the fiber, so that preferable air permeability and cushioning properties can be obtained. Further, if the single yarn fineness of the connecting yarn is 1500 dtex or less, the bending rigidity is not excessively increased, which is suitable for knitting a three-dimensional knitted fabric.

The edge cover material used for the cushion material of the present invention is not particularly limited as long as the difference in washing shrinkage (X1) and preferably (X2) from the three-dimensional knitted fabric is 0 ± 5.0. Any material such as non-woven fabric and leather may be used, and two or more may be laminated. The narrow slit method for the edge cover material may be either straight cut or bias cut. The fiber material used for the edge cover material is not particularly limited, and may be a synthetic fiber, a regenerated cellulose fiber, a natural fiber, or a fiber obtained by combining them. Further, the fineness of these fibers is not limited.
As a method of covering the outer periphery of the three-dimensional knitted fabric with the edge cover material, a sewing process, a fusion process, an adhesion process, or the like is used, but the sewing process is most preferable in consideration of handling properties and durability in the laminated type.

EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited only to an Example.
The evaluation method used in the present invention is as follows.
(1) Evaluation method of 40 ° C. washing shrinkage rate with a home-use washing machine (A) Prepare three samples each of three-dimensional knitted fabric and edge cover material cut into a size of 40 cm x 40 cm as an evaluation sample . With reference to the vicinity of the center of the surface of the sample, three length measurement sections (approximately 20 cm length) in the vertical and horizontal directions (about 20 cm length) are specified in advance with dots or lines, and the length of each length measurement section is specified. Measure it.
(B) The sample of (a) was washed in a fully automatic washing machine for home use (National NA-F60HP1 manufactured by Matsushita Electric Industrial Co., Ltd.) under washing conditions (warm water 40 ± 2 ° C., bath ratio 30: 1 (adjusted with load cloth) ), Detergent (Kao Co., Ltd. attack): 2 g / L, washed with course (main wash 5 minutes, rinse 2 times, dehydration 1 minute)) and air-dried. Next, measure the length of each of the three length measurement sections in the vertical and horizontal directions, and obtain the average value. The washing shrinkage rate is calculated by the following formula.
Shrinkage rate (%) = (original length L0−length L1 after washing) ÷ (original length L0) × 100
(C) The average value of the three samples is taken as the laundry shrinkage rate of the sample.

(2) Evaluation method of washing shrinkage rate at high temperature washing at 80 ° C. with a tumbler type washing machine (a) Three samples of three-dimensional knitted fabric and edge cover material cut into a size of vertical 40 cm × horizontal 40 cm as evaluation samples Prepare one by one. With reference to the vicinity of the center of the surface of the sample, three length measurement sections (approximately 20 cm length) in the vertical and horizontal directions (about 20 cm length) are specified in advance with dots or lines, and the length of each length measurement section is specified. Measure it.
(B) The sample of (a) was washed in a commercial fully automatic washing machine (W3130H manufactured by Electrolux Japan Co., Ltd.) under washing conditions (warm water 80 ± 2 ° C., bath ratio 30: 1 (adjusted with load cloth), Wash on course (5 minutes of main wash, 2 rinses, 1 minute of dehydration)) and let dry naturally. Next, measure the length of each of the three length measurement sections in the vertical and horizontal directions, and obtain the average value. The washing shrinkage rate is calculated by the following formula.
Shrinkage rate (%) = (original length L0−length L1 after washing) ÷ (original length L0) × 100
(C) The average value of the three samples is taken as the laundry shrinkage rate of the sample.

(3) Evaluation method of edge shape collapse of cushion material (a) A cushion (size 1 m × 1 m) is produced by sewing the outer periphery of a three-dimensional knitted fabric with an edge cover material.
(B) The evaluation cushion of (a) is washed according to the washing conditions described in the evaluation method of (1) and / or (2), and the appearance is observed. Appearance evaluation is performed by five people, and if there are 2 or more people who feel that they are out of shape, “no out of shape”, and if no more than 1 person, “no out of shape”. The number of evaluations is 3 times, and the average is the total judgment.

[Example 1]
Using a 9 gauge, 11.5mm double raschel machine equipped with 6 cocoons, 1 in 1 out of 280 dtex polyethylene terephthalate monofilament yarn from the two cocoons (L3, L4) located in the middle 1 334 dtex / 96 f polyethylene terephthalate multifilament yarn (167 dtex / 48 f × 2 aligned) is used as the ground yarn on the guides (L 1, L 2 and L 3, L 4) that form the front and back ground structures. Supplied in an in-out sequence. The setting was set to 20.7 course / 2.54 cm, and a three-dimensional knitted knitted fabric with a turtle shell pattern of 8-course mesh on the front and back sides was knitted.

This three-dimensional knitted fabric is scoured at 70 ° C and then finished with a tentering heat set (180 ° C), and the cushion member has a thickness of 8.1 mm, a weight of 28.0 course / 2.54 cm, and 10.0 wale / 2.54 cm. Got. The 40 degreeC washing shrinkage rate by a household washing machine was length: -0.8%, width: + 2.6%.
The outer periphery of the cushion member obtained by cutting the three-dimensional knitted fabric into a length of 1 m and a width of 1 m, an edge cover material of PET taffeta and a vertical slit in the vertical direction (40 ° C washing shrinkage by a home washing machine is vertical: + 0.1%, horizontal: + 0.3%) was produced as a cushioning material, washed at 40 ° C. with a household washing machine, and the appearance around the edge after drying was observed. The evaluation results are shown in Table 1.

[Example 2]
Using a 18-gauge double raschel machine equipped with 6 cocoons and a 12.0mm gap between the hooks, 200-dtex polytrimethylene terephthalate monofilament yarn is connected in 1 inch from two cocoons (L3, L4) located in the middle 334dtex / 96f polyethylene terephthalate multifilament yarn (167dtex / 48f x 2 pieces) as a ground yarn on the ridge (L1, L2, L3, L4) guides that are supplied in a 1-out arrangement and form the front and back ground structures Were supplied in a 1 in 1 out sequence. The setting was set to 20.7 course / 2.54 cm, and a three-dimensional knitted knitted fabric with 12-mesh mesh on the front and back sides was knitted.

This three-dimensional knitted fabric is scoured at 70 ° C. and then finished with a tentering heat set (180 ° C.). The cushion member has a thickness of 8.0 mm, a weight of 32.0 course / 2.54 cm, and a 12.6 wale / 2.54 cm. Got. The 40 degreeC washing shrinkage rate by a household washing machine was length: -1.4%, width: + 3.1%.
A cushioning material was produced and evaluated in the same manner as in Example 1 except that the three-dimensional knitted fabric was changed to the three-dimensional knitted fabric. The evaluation results are shown in Table 1.

[Example 3]
Using a 22 gauge, 5.2 mm double raschel machine equipped with 5 reeds, 110 dtex polyethylene terephthalate monofilament yarns are fed in an all-in array from the reed (L3) located in the middle as a connecting thread. A 167 dtex / 48f polyethylene terephthalate multifilament yarn is supplied in a 3-in-1 out arrangement as a ground yarn to the ridge (L1, L2) guide forming the ground texture of the ridge (L4, L5) ) A 167 dtex / 48f polyethylene terephthalate multifilament yarn false twisted yarn was supplied to the guide in an all-in arrangement. Setting was 31.8 course / 2.54 cm, and a three-dimensional knitted fabric with a turtle shell pattern with an 8-course mesh on the front surface and a half structure on the back surface was knitted.

This three-dimensional knitted fabric is scoured at 70 ° C, then finished with a tentering heat set (180 ° C), and a cushion member having a thickness of 4.5 mm, a property of 35.0 course / 2.54 cm, and 22.2 wale / 2.54 cm Got. The washing shrinkage rate at 40 ° C by a household washing machine is vertical: + 0.5%, horizontal: + 1.5%, and the washing shrinkage rate at high temperature washing at 80 ° C by a tumbler type washing machine is vertical: + 4.1%, Horizontal: + 4.8%.
As the edge cover material, PET tricot brushed product vertical slit (40 ° C washing shrinkage by household washing machine is vertical: + 2.6%, horizontal: + 3.3%, 80 ° C high temperature by tumbler type washing machine) Washing shrinkage rate at the time of washing is vertical: + 3.0%, width: + 3.5%), and after producing cushioning material in the same manner as in Example 1, washing at 40 ° C. and tumbler type washing by a household washing machine Washing was performed at 80 ° C. using a machine, and the appearance around the edge after drying was observed.

[Example 4]
Using a 22-gauge double raschel machine with a 3.2 mm gap between 6 hooks, 110-dtex polytrimethylene terephthalate monofilament yarn is connected in 1-in-1 from the two pieces (L3, L4) located in the middle. 112dtex / 36f (56dtex / 18f x 2 pieces) polyethylene terephthalate multifilament yarn is supplied as a ground yarn to the guides (L1, L2 and L5, L6) which are supplied in an out arrangement and form the front and back ground structures. Supplied in a 1 in 1 out sequence. The setting was set to 23.3 course / 2.54 cm, and a front and back 4 course mesh diamond pattern solid knitted fabric was knitted.

This three-dimensional knitted fabric is scoured at 70 ° C, then finished with a tentering heat set (180 ° C), and a cushion member having a thickness of 2.2 mm, a weight of 27.5 course / 2.54 cm, and a 17.2 wale / 2.54 cm Got. The 40 ° C. washing shrinkage ratio of the household washing machine was vertical: + 3.3%, and horizontal: + 1.5%.
A cushion material was produced and evaluated in the same manner as in Example 1 except that the above-described three-dimensional knitted fabric was laminated on the upper layer of the three-dimensional knitted fabric of Example 1. The evaluation results are shown in Table 1.

[Example 5]
Example 1 except that a vertical slit of PET tricot brushed product (40 ° C washing shrinkage by household washing machine is vertical: + 2.6%, horizontal: + 3.3%) is used as the edge cover material. Similarly, after producing a cushioning material, washing at 40 ° C. by a household washing machine was performed, and appearance around the edge after drying was observed. The evaluation results are shown in Table 1.

[Comparative Example 1]
Using an 18-gauge, 8.5mm double raschel machine equipped with 6 cocoons, 244 dtex 6 nylon monofilament yarns are connected in 1-in-3 out from the two cocoons (L3, L4) located in the middle. 1 in 3 out arrangement of 334 dtex / 96 f (167 dtex / 48 f × 2 aligned) polyethylene terephthalate multifilament yarns as ground yarn supplied to the wrinkle (L1, L2) guide forming the surface texture 167 dtex / 48f polyethylene terephthalate multifilament yarn was fed in an all-in arrangement as the ground yarn to the ridge (L5, L6) guide forming the ground texture on the back surface. The setting was set to 20.7 course / 2.54 cm, and a three-dimensional knitted fabric of back side insertion knitting was knitted with a turtle shell pattern having a 16-course mesh surface.

This three-dimensional knitted fabric is scoured at 70 ° C, then finished with a tentering heat set (180 ° C), and a cushion member having a thickness of 6.1 mm, a weight of 25.0 course / 2.54 cm, and a 9.5 wale / 2.54 cm Got. The 40 ° C. washing shrinkage ratio of the home washing machine was vertical: + 1.2% and horizontal: + 9.5%.
A cushion material was produced and evaluated in the same manner as in Example 1 except that the solid knitted fabric of Example 1 was changed to the above-described solid knitted fabric. The evaluation results are shown in Table 1.

[Comparative Example 2]
Three-dimensional knitted fabric of Example 3 and vertical slit of cotton smooth circular knitted fabric as an edge cover material (40 ° C washing shrinkage rate by household washing machine is vertical: + 8.8%, horizontal: + 4.9%) A cushioning material was produced in the same manner as in Example 1 except that it was used, followed by washing with a household washing machine, and the appearance around the edge after drying was observed. The evaluation results are shown in Table 1.

  The cushion material obtained by coating the outer periphery of the three-dimensional knitted fabric of the present invention with an edge cover material can be suitably used in the fields of bedding such as bed pads and pillow covers, cushions, and mats.

Claims (3)

A cushion material obtained by coating the outer periphery of a cushion member obtained by laminating one or a plurality of three-dimensional knitted fabrics composed of front and back two-layer knitted fabric and connecting yarns connecting the two-layer knitted fabric with an edge cover material. The cushioning material is characterized in that the difference in washing shrinkage (X1) when washing at 40 ° C. by a household washing machine is 0 ± 5.0 in both the vertical and horizontal directions.
Here, the laundry shrinkage rate difference (X1) = the laundry shrinkage rate of the three-dimensional knitted fabric (A1) −the laundry shrinkage rate (B1) of the edge cover material. The cushioning material according to claim 1, wherein a difference in washing shrinkage (X2) during high-temperature washing at 80 ° C by a tumbler-type washing machine is 0 ± 5.0 in both the vertical and horizontal directions.
Here, the laundry shrinkage rate difference (X2) = the laundry shrinkage rate of the three-dimensional knitted fabric (A2) −the laundry shrinkage rate of the edge cover material (B2).   The cushion material according to claim 1 or 2, wherein the connecting yarn of the three-dimensional knitted fabric is a monofilament of 10 to 1500 dtex.