JP2007307135A - Intermediate material for pillow, and pillow - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an intermediate material for a pillow, which imparts a good feeling of holding and corrects a sensation of heat accumulation and sweatiness mainly in the neck. <P>SOLUTION: The intermediate material for a pillow is interposed between a core material and a pillow cover, and a three-dimensional knitted fabric made up of two layers of a knitted fabric for the obverse and the reverse and connecting threads connecting the obverse and the reverse. The three-dimensional knitted fabric is an intermediate material having the connecting threads having a total area (NT/1×10<SP>6</SP>ρ<SB>0</SB>) of 0.02 to 0.25 cm<SP>2</SP>in the area of a 2.54 cm square (6.45 cm<SP>2</SP>) when the number of connecting threads in the area of a 2.54 cm square (6.45 cm<SP>2</SP>) is N (number/6.45 cm<SP>2</SP>), dtex of the connecting threads is T (g/1×10<SP>6</SP>cm), and the density of the connecting threads is denoted by ρ<SB>0</SB>(g/cm<SP>3</SP>). <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an intermediate material for pillows that has an excellent hold feeling and has improved heat storage and stuffiness in the neck.

Pillows are said to be optimal pillows that gently support the neck and have a so-called hold feeling that naturally catches the roundness of the back of the head, and are less likely to feel heat accumulation and stuffiness around the neck.
Pillows with a good hold feeling are preferred, such as pillows that gently sink the head and wrap the roundness of the back of the head, such as low-resilience urethane, but such pillows appear to have been wrapped in the back of the head and neck Therefore, it feels heat storage and stuffiness around the neck.
On the other hand, in order to improve the feeling of heat accumulation and stuffiness centering on the neck, a method of forming an air layer capable of releasing and releasing moisture between the back of the head and the neck and the pillow is considered. When formed, the feeling of holding is impaired, so it is difficult to satisfy both.
Conventionally, for example, as disclosed in Patent Document 1, interposing a three-dimensional knitted fabric composed of a front and back two-layer knitted fabric and a connecting thread connecting the two-layer knitted fabric between a pillow material and a pillow cover Although known, its purpose is merely to eliminate stuffiness, and there is no description or suggestion of aiming at having an excellent hold feeling.

JP 2005-152480 A

  An object of the present invention is to provide an intermediate material for a pillow which has an excellent hold feeling and which has improved heat storage feeling and stuffiness centered on the neck.

As a result of repeating detailed studies in order to solve the above problems, the present inventor has solved the above problems by using a specific three-dimensional knitted fabric as a pillow intermediate material interposed between the pillow core material and the pillow cover. As a result, the present invention has been made.
That is, the present invention is as follows.
(1) An intermediate material for a pillow interposed between a pillow core material and a pillow cover, the intermediate material for pillow being composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabrics This three-dimensional knitted fabric has a number of connecting yarns in the area of 2.54 cm square (6.45 cm ² ) of the three-dimensional knitted fabric, N (lines / 6.45 cm ² ), and the dtex of the connecting yarn is T ( g / 1 × 10 ⁶ cm) and the density of the connecting yarn is ρ ₀ (g / cm ³ ), the total cross-sectional area of the connecting yarn in the area of 2.54 cm square (6.45 cm ² ) of the three-dimensional knitted fabric (6.45 cm ² ) (N · T / 1 × 10 ⁶ · ρ ₀ ) is 0.02 to 0.25 cm ² .
(2) The intermediate material for pillows according to (1), wherein the connecting yarn of the three-dimensional knitted fabric is composed of a monofilament yarn.
(3) The intermediate material for pillow according to any one of (1) and (2) above, wherein the thickness of the three-dimensional knitted fabric is 2 to 30 mm.
(4) A pillow composed of the pillow intermediate material according to any one of (1) to (3) above.

  The intermediate material for pillow according to the present invention is excellent in a feeling of holding and improves a feeling of heat accumulation and a feeling of stuffiness centering on the neck.

The present invention will be specifically described below.
As the pillow core material to be combined with the pillow intermediate material of the present invention, conventionally known pillow core materials, for example, various urethane materials including low resilience urethane foam, synthetic fiber cotton such as polyester fiber, plastic hollow and solid There are so-called synthetic polymer materials such as pipe materials, buckwheat, camel hair, feathers, natural materials such as cotton and one or more combinations thereof, but in the present invention, heat dissipation is inferior to natural materials, It is useful in combination with a so-called synthetic polymer material that is easily swelled. Particularly, various urethane materials including low-resilience urethane foam are the most useful and effective combinations because of poor heat dissipation. In addition, the pillow core material using part or all of the urethane material has an excellent hold feeling as compared with other pillow core materials, and this combination is an optimal combination in the present invention.

In addition, as a pillow cover to be combined with the pillow intermediate material of the present invention, a conventionally known pillow cover can be used. However, a pillow cover that is particularly excellent in hygroscopicity and water absorption from the comfort such as touch is preferable. And natural fibers such as silk and wool, cupra, rayon, purified cellulose fibers, cellulose fibers such as acetate (di and triacetate), etc. Examples thereof include woven and knitted fabrics in which one or more synthetic fibers such as modified polyester and polyamide are combined, and those obtained by raising these.
The form of the intermediate material for pillow of the present invention may be a form covering the whole pillow core material, a form covering only the upper surface and the side surface where the head abuts except the bottom surface of the pillow core material, and further the entire upper surface. Or the form laminated | stacked on the part which the head contact | abuts, ie, the part which considered the movement of the head by turning over, etc. is mentioned, However, What is necessary is just to use the intermediate material for pillows of this invention at least in the part which a head contacts. In particular, it is preferable that the head is laminated on the portion where the head abuts and is covered with a conventionally known pillow cover so that there is little change in the form and shape of the pillow, and the manufacture of the pillow is simple and preferable.

The pillow of the present invention is characterized by using a three-dimensional knitted fabric as an intermediate material. The three-dimensional knitted fabric needs to have a total cross-sectional area of the connecting yarn within a specific range.
That is, the number of connecting yarns in an area of 2.54 cm square (6.45 cm ² ) of a three-dimensional knitted fabric is N (pieces / 6.45 cm ² ), dtex of the connecting yarns is T (g / 1 × 10 ⁶ cm), When the density of the connecting yarn is ρ ₀ (g / cm ³ ), the total cross-sectional area (N · T / 1 × 10 ⁶ · ρ ₀ ) of the connecting yarn in the area of the solid knitted fabric 6.45 cm ² is 0. must be 02～0.25Cm ^2, preferably 0.04 cm ² or more, particularly 0.07 cm ² or more is preferable, 0.2 cm ² or less, in particular 0.15 cm ² or less.
By setting within this range, a pillow with particularly excellent hold feeling and improved heat storage feeling and stuffiness around the neck can be obtained.
The connecting yarns may be looped stitches formed on the front and back knitted fabrics, or may have a structure in which they are hooked on the front and back knitted fabrics, but at least two connecting yarns reverse the knitted fabrics on the front and back sides. In order to improve the form stability of the three-dimensional knitted fabric, it is preferable to incline in the direction and connect it in a cross shape (X shape) or a truss shape.

Next, if the total cover factor (TCF) of the knitted fabric on the surface of the three-dimensional knitted fabric is 750 to 1250, preferably 800 to 1200, more preferably 850 to 1150, and particularly preferably 950 to 1100, the fit with the pillowcase It is a good and comfortable pillow.
Here, the total cover factor (TCF) is calculated by the following equation.
Total cover factor (TCF) =
Course Cover Factor (CCF) + Wale Cover Factor (WCF)
However, course cover factor (CCF) = (number of courses; book / 2.54 cm) × (thickness of yarn constituting surface knitted fabric; dtex) ^1/2
Wale cover factor (WCF) = (number of wales; number / 2.54 cm) × (thickness of the yarn constituting the surface knitted fabric; dtex) ^1/2

The thickness of the yarn constituting the surface knitted fabric refers to the thickness of the yarn constituting the stitch existing in the area of 2.54 cm square (6.45 cm ² ) of the surface knitted fabric. 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.

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.
Further, the ratio of the course cover factor (CCF) / the wale cover factor (WCF) (CCF / WCF) is preferably 1.0 to 2.5, and particularly preferably 1.3 to 2.0.
Here, the surface knitted fabric refers to the surface in contact with the pillow cover. If the front and back sides cannot be distinguished, the total cover factor (TCF) of the knitted fabric on either side may be 750 to 1250, and the total cover factor of the knitted fabric on the other side is not limited. .

The fiber material constituting the three-dimensional knitted fabric will be described. First, the surface knitted fabric is preferably excellent in hygroscopicity and water absorption, for example, natural fibers such as cotton, hemp, silk, wool, cupra, rayon, purified cellulose. Examples thereof include cellulose fibers such as fibers and acetates (di- and triacetates), and examples thereof include irregular cross-section yarns such as W type, synthetic fibers such as polyester fibers and polyamide fibers modified in hygroscopicity and water absorption, and the like. There are round, triangular, L-shaped, T-shaped, Y-shaped, W-shaped, Yaba-shaped, flat-shaped, dog-bone shaped, etc. May be any of the original yarn (unprocessed yarn), spun yarn, twisted yarn, false twisted yarn, fluid jet yarn, etc., and may be multifilament yarn or monofilament yarn. And / or cross section Entangling different two or more kinds of states, 交撚, composite false twisting, it may be used to mix with known combined means such mixed knitting.
Moreover, there is no restriction | limiting in particular about the knitted fabric of a back surface, The thing of the same fiber material, a cross section, and a form as the knitted fabric of a surface can be used.
The preferred thickness of the fiber material constituting the front and back knitted fabrics is preferably 50 to 300 in terms of total dtex, particularly preferably 100 to 250, and the single yarn dtex is preferably 0.1 to 7, and particularly preferably 0.5 to 6. preferable.

Furthermore, as a connecting yarn that connects these front and back knitted fabrics, a monofilament yarn is preferable from the viewpoint of relaxation of misalignment force, polytrimethylene terephthalate fiber, polybutylene terephthalate fiber, polyester fiber such as polyethylene terephthalate fiber, Fibers of any material such as polyamide fibers, polypropylene fibers, polyvinyl chloride fibers, polyester elastomer fibers can be used. Among them, polytrimethylene terephthalate fibers are used as at least a part of the connecting yarns. It has a cushioning property with elasticity, and is preferable because the durability of the cushioning property after repeated or long-time compression is good. 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 However, a round cross section is preferable for improving the durability of the cushioning property of the three-dimensional knitted fabric.
The connecting yarn is optimally 100% monofilament yarn, but multifilament raw yarn or false twisted yarn may be mixed, and in that case, the monofilament yarn is composed of 30% by mass or more, particularly 50% by mass or more. Is preferred.
The preferred thickness of the connecting yarn is 10 to 1000 dtex, particularly 20 to 500 dtex in the case of monofilament yarn, and preferably 10 to 1000 dtex, particularly 20 to 500 dtex in total dtex in the case of multifilament yarn, and the single yarn dtex is 1 to 1. 7 is preferable, and 2 to 6 is particularly preferable.

The surface knitted fabric of the three-dimensional knitted fabric of the present invention is preferably used so as not to expose the monofilament yarn used in the connecting yarn so as to reduce the feeling of roughness. As a method of suppressing the exposure of the monofilament yarn, in addition to setting the total cover factor of the present invention within a specific range, the supply tension of the monofilament yarn can be increased by increasing the fineness of the multifilament yarn compared to the fineness of the monofilament yarn. To increase the multi-yarn feed tension, to feed the multi-yarn on the overfeed side from the normal feed rate, to increase the number of filaments of the multi-yarn, to knitting with a double raschel knitting machine, It is preferable to perform knitting by a method such as supplying yarns at least in the same direction as the overlap direction with respect to the needles of the multi-yarn.
Further, the relationship between the total fineness D (decitex) of the multi-yarn and the fineness d (decitex) of the connecting yarn in the same stitch of the surface knitted fabric is preferably 1.1 or more, more preferably D / d. Is 1.5-15.0.

In the case of D / d <1.1, the uniform coverage of the monofilament yarn by the multi-yarn is lowered, and there is a case where the feeling of roughness on the knitted fabric surface cannot be suppressed.
Furthermore, it is only necessary to increase the coverage of the fibers constituting the surface, and it is preferable to use bulky yarns such as false twisted yarns and spun yarns as multifilament yarns constituting the surface. A false twisted yarn of a modified cross-section polyester synthetic fiber such as W-type is preferred.
In the three-dimensional knitted fabric, insertion yarns (monofilament yarns and / or multifilament yarns) may be linearly inserted in the warp direction and / or the transverse direction of at least one of the front and back knitted fabrics.
Further, the thickness of the three-dimensional knitted fabric is preferably 2 mm or more, particularly 3 mm or more, more preferably 5 mm or more, and preferably 30 mm or less, particularly 20 mm or less, and further 15 mm or less.

The three-dimensional knitted fabric of the present invention can be knitted with a knitting machine having two opposite rows of needle beds, and can be knitted with a double raschel knitting machine, a double circular knitting machine, a flat knitting machine with a V bed, etc. In order to obtain a high-quality three-dimensional knitted fabric, it is preferable to use a double raschel knitting machine. The gauge of the knitting machine is preferably 9 gauge to 28 gauge.
The knitted fabrics on the front and back sides of the three-dimensional knitted fabric do not have to have the same knitted structure, and may be different knitted structures. Although lightness and air permeability may be improved, it is preferable that the air permeability is improved by making the surface a flat structure so that the touch is good and the back surface is a knitted fabric having a mesh-like opening. Further, when the surface is raised, a material having a better touch can be obtained.

The fibers used for the front and back knitted fabrics or connecting yarns of the present invention may be uncolored or colored.
Coloring methods include pre-spinning dyeing with uncolored yarn in the form of skein or cheese, undiluted solution coloring method in which pigment, dye, etc. are mixed in the undiluted undiluted solution, and dyeing or printing in a three-dimensional knitted form However, since it is difficult to maintain the three-dimensional shape or the processability is poor when dyeing in a three-dimensional knitted form, a pre-dyed method or a stock solution coloring method is preferable.
As a method for finishing the three-dimensional knitted fabric, when the three-dimensional knitted fabric is used uncolored, or in the case of a three-dimensional knitted fabric using a pre-dyed yarn or a stock solution colored yarn, the raw machine can be finished through processes such as scouring and heat setting. In the case where either the connecting yarn or the front and back yarns are uncolored solid knitted fabric, the raw machine can be finished through processes such as scouring, dyeing and heat setting.

The finished three-dimensional knitted fabric can be processed into the desired shape by means of fusing, sewing, piping, resin processing, etc., or by thermoforming, etc. It is better not to feel it, and it is preferable to process by piping. The piping material may be arbitrarily selected in consideration of the thickness of the sewing portion, the jumping of the connecting thread, and the durability during use. In addition, since the piping part may be damaged due to stress concentration due to washing or the like, it is preferable to sew with a double stitch or the like.
In constructing an intermediate material for a pillow using such a three-dimensional knitted fabric, it is preferable to construct it with a single three-dimensional knitted fabric in terms of production of the intermediate material for pillows in terms of cost and productivity. A knitted fabric may be laminated. However, when laminating a three-dimensional knitted fabric, the thickness of the intermediate material for pillow is preferably 2 mm or more, particularly preferably 3 mm or more, more preferably 5 mm or more, and 30 mm or less, particularly preferably 20 mm or less, and further preferably 15 mm or less.

Hereinafter, the present invention will be described more specifically based on examples and the like, but the present invention is not limited to these examples and the like.
The measurement method and evaluation method in the present invention are as follows.
(1) Evaluation of pillow intermediate material Commercially available low-resilience urethane worm as a pillow core material, the pillow intermediate material obtained in the example was laminated only on the upper surface of the pillow core material, and 100% cotton commercially available from above. A pillow cover that covered the whole of the pillow core material and the pillow intermediate material was used.
Evaluation was based on an average score of 10 women using a commercial bed.
"Hold feeling"
3 points: Excellent hold feeling 2 points: Neither can be said 1 point: Inferior hold feeling "Heat storage feeling and stuffiness around the neck"
3 points: hardly feel 2 points: feel 1 point: feel pretty

[Example 1]
Using a 22 gauge, 4.2 mm double raschel knitting machine equipped with 6 rivets, a 167 dtex / 48f W-shaped polyethylene terephthalate system on 2 creases (L1, L2) forming the surface knitted fabric Two folds (L5, L6) that form a knitted fabric on the back side by supplying all false-twisted yarn (made by Asahi Kasei Fiber Co., Ltd., trademark “Technofine” false-twisted yarn) in an all-in arrangement. In addition, the same false twisted yarn is supplied in a 3 in 1 out arrangement, and 33 dtex nylon 66 fiber monofilament yarn (density 1.14) is supplied in an all in arrangement to the L3 heels forming the connecting yarn. Then, a raw machine of a three-dimensional knitted fabric with a surface knitted fabric density of 33.3 course / 2.54 cm and 24.8 wale / 2.54 cm was knitted with the following structure.
L1: 2422/2022 /
L2: 2022/4644 /
L3: 0220/2002 /
L5: 4420/2224/2220/2242/4468/6664/6668/6646 /
L6: 4468/6664/6668/6646/4420/2224/2220/2242 /
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 is 35.0 course / 2.54 cm, 22.2 wale / 2.54 cm, and the total cross-sectional area of the connecting yarn is 0.04 cm ² (the number of connecting yarns ( N) was 1554 / 6.45 cm ² ).
The evaluation results of this three-dimensional knitted fabric were excellent, with a hold feeling of 2.8 points, a heat storage feeling centered on the neck and a stuffiness feeling of 2.2 points.

[Comparative Example 1]
In Example 1, without using a commercially available 100% cotton pillow cover, the result of evaluation in a state in which the pillow core material and the three-dimensional knitted fabric were laminated was 2.8 points of hold feeling, The stuffiness was 1.5 points.
[Comparative Example 2]
In Example 1, the evaluation result without using the three-dimensional knitted fabric as an intermediate material was a hold feeling of 2.8 points, a heat storage feeling centered on the neck and a feeling of stuffiness of 1.2 points.

[Examples 2-6, Comparative Examples 3-4]
In Example 1, a three-dimensional knitted fabric having a total cross-sectional area of the connecting yarn of 0.01 to 0.30 was finished by changing the dtex of the connecting yarn, the density design of the green machine, and the width at the time of finishing.
The total cross-sectional area of the connecting yarn is 0.02 cm ² (Example 2) when the hold feeling is 2.8 points, the heat storage feeling around the neck and the feeling of stuffiness 2.0 points, 0.07 cm ² (Example 3) Is a hold feeling of 2.8 points, heat storage feeling and stuffiness feeling around the neck 2.4 points, 0.15 cm ² (Example 4) is a hold feeling 2.6 points, a heat storage feeling around the neck and Mule feeling 2.4 points, 0.20 cm ² (Example 5) is a hold feeling 2.5 points, heat accumulation feeling and sensation feeling 2.5 points 0.25 cm ² (Example 6) around the neck The hold feeling was 2.3 points, and the heat storage feeling and stuffiness feeling 2.5 points centered on the neck, and the hold feeling and the heat storage feeling and stuffiness feeling centered on the neck were excellent as in Example 1. .
On the other hand, when the total cross-sectional area of the connecting yarn is 0.01 cm ² (Comparative Example 3), the hold feeling is 2.8 points, the thermal storage feeling and the stuffiness feeling centered on the neck is 1.3 points, and 0.30 cm ² (Comparative Example). 4) was inferior to either a hold feeling of 1.5 points, a heat storage feeling centered on the neck or a feeling of stuffiness of 2.5 points.

[Example 7]
Using a double raschel knitting machine with 6 gauges and a 10 mm hook between the hooks, two ridges (L1, L2) forming the surface knitted fabric are made of polyethylene terephthalate fibers with a W-shaped cross section of 167 dtex / 48f. 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. All of the same false twisted yarns are supplied in a 3 in 1 out arrangement, and 200 dtex of polyethylene terephthalate fiber monofilament yarn (density 1.38) is supplied in an all in arrangement on the L3 heel forming the connecting yarn. The three-dimensional knitting machine was knitted with the following organization.
L1: 2422/2022 /
L2: 2022/4644 /
L3: 0220/2002 /
L5: 4420/2224/2220/2242/4468/6664/6668/6646 /
L6: 4468/6664/6668/6646/4420/2224/2220/2242 /
The obtained raw machine was scoured according to a conventional method and finished by dry heat setting.
The finished three-dimensional knitted fabric has a structure with a flat surface knitted fabric, a back knitted fabric with a mesh structure thickness of 8.0 mm, and a surface knitted fabric density of 31.0 course / 2.54 cm, 10.2 wales / The total cross-sectional area of the connecting yarn was 0.09 (the number (N) of connecting yarns was 632 / 6.45 cm ² ).
The evaluation results of this three-dimensional knitted fabric were excellent, with a hold feeling of 2.8 points, a heat storage feeling centered on the neck and a feeling of stuffiness of 2.8 points.

  The present invention is an intermediate material for a pillow that is excellent in a hold feeling and improves a heat storage feeling and a stuffiness centered on the neck by using a specific three-dimensional knitted fabric, and is used as an intermediate material for a pillow.

Claims (4)

A three-dimensional knitted fabric comprising a pillow intermediate material interposed between a pillow core material and a pillow cover, wherein the pillow intermediate material is composed of two layers of front and back knitted fabrics and connecting yarns connecting the two layers of knitted fabrics. In this three-dimensional knitted fabric, 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 (lines / 6.45 cm ² ), and the dtex of the connecting yarn is T (g / 1). × 10 ⁶ cm) and the density of the connecting yarn is ρ ₀ (g / cm ³ ), the total cross-sectional area (N · T) of the connecting yarn in the area of 2.54 cm square (6.45 cm ² ) three-dimensional knitted fabric / 1 × 10 ⁶ · ρ ₀ ) is 0.02 to 0.25 cm ² .   The intermediate material for pillow according to claim 1, wherein the connecting yarn of the three-dimensional knitted fabric is composed of a monofilament yarn.   The pillow intermediate material according to claim 1 or 2, wherein the three-dimensional knitted fabric has a thickness of 2 to 30 mm.   The pillow comprised with the intermediate material for pillows in any one of Claims 1-3.