JP2019052391A - Composite fabric - Google Patents

Abstract

To provide a composite fabric capable of becoming a light and thick artificial leather excellent in cushioning properties, and applying to a light clothing product having characteristics such as moisture-transmission waterproof.SOLUTION: A composite fabric 10 comprises multiple knit stitches obtained by forming same stitches with N (N≥2) yarns, and a double-sided circular knitting fabric 11 having rib yarns connected with one or more yarns and (N-1) or less yarns of N yarns by tack stitches as a fibrous base material. A layer 12 of a synthetic resin is formed on the double sided circular knitting fabric 11. Thus, a bulky configuration is possible especially in a part configured by the rib yarns of a stitch structure of the double-sided circular knitting fabric 11, and a thickness of the composite fabric 10 is increased while lightness is sustained to give an artificial leather excellent in cushioning properties.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite fabric using a double-sided circular knitted fabric as a base material.

  BACKGROUND ART Composite fabrics obtained by integrating a synthetic resin material with fabrics (fibrous substrates) such as woven fabrics, knitted fabrics, and nonwoven fabrics are used in various technical fields. In particular, a composite fabric exhibiting a genuine leather-like appearance is used in various applications as a synthetic leather that is a substitute for natural leather. Such synthetic leather is manufactured by a manufacturing method suitable for the application, with a fibrous base material and a synthetic resin material selected according to the purpose and application.

  For example, in order to obtain a good-looking synthetic leather that is hard to see seams and needle holes as an interior material that covers interior parts such as automobile seats and chairs, a urethane resin layer is used on the surface using a tricot knitted fabric as a fibrous base material. A technique for stacking has been developed (Patent Document 1).

  In addition, the double raschel knitted fabric is used as the fibrous base material in order to obtain a beautiful appearance by preventing the transfer of dye from the fibrous base material to the surface resin layer, as well as excellent cushioning and surface resin layer peeling resistance. Synthetic leather having a synthetic resin layer formed on its surface has been developed (Patent Document 2).

  Synthetic leather made of warp knitted fabrics such as these tricot knitted fabrics and double raschel knitted fabrics does not have sufficient stretchability, so the followability to complicated three-dimensional shapes such as automobile seats is poor, and the surface of interior parts is wrinkled. There is a problem that is likely to occur. Therefore, synthetic leather has been developed in which a circular knitted fabric is used as a fibrous base material as a weft knitted fabric having superior stretchability, and a surface layer and a protective layer made of polyurethane resin are sequentially laminated on the surface (patent document). 3).

JP 2010-111989 JP 2014-029050 A International Publication No. 2015/001732

  However, since the synthetic leather of Patent Document 3 is insufficient in bulkiness of the circular knitted fabric that is a fabric and does not have a sufficient thickness, polyurethane resin is the same as the circular knitted fabric in order to ensure cushioning properties as a synthetic leather. It is laminated with a thickness of about a degree and becomes heavy as a whole. As a result, the interior material using the synthetic leather of Patent Document 3 has a problem that it cannot meet the recent demand for weight reduction of aircrafts and automobiles. Moreover, in the synthetic leather of patent documents 1 and 2, it is necessary to make a synthetic resin layer thick for the same reason, and it becomes a material lacking in lightness. Therefore, these materials are not suitable for applications other than synthetic leather, such as sports clothing.

  The present invention has been made in view of such problems, and is a lightweight and thick synthetic leather having excellent cushioning and strength, and lightweight with moisture permeability and waterproof properties. It aims at providing the composite fabric which can be applied also to clothing etc.

  In order to achieve the above object, a composite fabric according to a first aspect of the present invention is a composite fabric including a double-sided circular knitted fabric knitted using long fibers and / or short fibers, the double-sided circular knitting The ground is provided with multiple knit stitches forming the same stitch with N yarns (N ≧ 2), and one or more of the N yarns forming the multiple knit stitches, and (N−1) yarns or less. And a double-sided circular knitted fabric that is coated and / or laminated and / or impregnated with a synthetic resin.

  In the surface having the multiple knit stitches, the ratio of the multiple knit stitches to the total stitches is preferably in the range of 20% to 100%.

  It is preferable that an original yarn is used for at least a part of the double-sided circular knitted fabric, and the double-sided circular knitted fabric is not dyed.

  It is preferable that one side of the double-sided circular knitted fabric is brushed.

  It is preferable that the surface of the double-sided circular knitted fabric is not brushed.

  The composite fabric according to the present invention has a light weight and thickness, and is excellent in cushioning and strength because the bulky and light double-sided circular knitted fabric is subjected to at least one treatment of synthetic resin coating, lamination or impregnation. It can be applied to lightweight clothing and the like having characteristics such as moisture permeability and waterproofness.

It is a perspective view which shows typically the composite fabric which concerns on embodiment of this invention. It is sectional drawing which shows typically the II cross section of the composite fabric which concerns on embodiment. 1 is a schematic diagram showing a stitch structure of a double-sided circular knitted fabric constituting a composite fabric according to Example 1. FIG. 3 is a schematic diagram showing a stitch structure of a double-sided circular knitted fabric used for the composite fabric of Comparative Example 1. FIG. 5 is a schematic view showing a stitch structure of a double-sided circular knitted fabric used for the composite fabric of Comparative Example 2. FIG.

  Hereinafter, embodiments of the present invention will be described in detail.

  A composite fabric according to an embodiment of the present invention is a composite fabric including a double-sided circular knitted fabric knitted using long fibers and / or short fibers, and has N double-sided circular knitted fabrics (N ≧ 2). A multi-knit stitch forming the same stitch with the yarn, and having one or more of N yarns forming a multi-knit stitch, and a rib yarn connected with (N-1) yarns or less and tuck stitches And a composite fabric in which a double-sided circular knitted fabric is coated and / or laminated and / or impregnated with a synthetic resin.

  More specifically, the composite fabric according to the present embodiment is knitted with long fibers and / or short fibers as a constituent element, and is connected to one or more yarns forming a multi-knit stitch with tuck stitches. It is characterized by having a double-sided circular knitted fabric having a rib yarn.

  That is, the double-sided circular knitted fabric of the composite fabric according to the present embodiment has, for example, a double stitch as a multi-knitted stitch, and a structure in which a tack stitch is caught only on one of the double stitches. Thereby, it can be set as the double-sided circular knitted fabric in which a tack stitch does not come out on the surface, and it becomes the structure by which the tack stitch is arrange | positioned only on the back surface. Accordingly, the bulkiness is increased, and a double-sided circular knitted fabric having a feeling of swelling and strength is obtained.

  The double-sided circular knitted fabric is subjected to at least one treatment among coating, laminating and impregnation. That is, the composite fabric according to the present embodiment may be a double-sided circular knitted fabric constituting the composite fabric that is only coated, only laminated, or only impregnated. Further, it may be laminated after being coated, coated after being impregnated, or laminated after being impregnated. Alternatively, it may be a composite fabric coated after being impregnated and further laminated.

  Here, the coating means that the surface of the double-sided circular knitted fabric is coated with a fluid synthetic resin such as a synthetic resin solution or a molten liquid on the surface (one side or both sides) of the double-sided circular knitted fabric. Is a process of covering with a synthetic resin or the like. More specifically, a resin layer such as polyurethane or acrylic is formed on one side of the fabric by a knife coater or the like.

  Lamination is a process of attaching a film or sheet of synthetic resin or the like to the surface (one side or both sides) of a double-sided circular knitted fabric with an adhesive or the like. For example, a resin solution is applied to a releasable substrate such as a release paper with a knife coater and dried, and a double-sided circular knitted fabric is pasted on this, and the release paper is peeled off after a predetermined time to form a laminate layer There is a way to do it. Further, there is a method in which an adhesive resin is applied to one side of a knitted fabric with a gravure roll or the like, and then a laminate layer is formed by bonding the knitted fabric and a resin film such as polyurethane with the adhesive resin.

  Furthermore, the impregnation is a process in which a liquid material such as a synthetic resin solution or a molten liquid is immersed from the surface of the double-sided circular knitted fabric to fill the voids inside the knitted fabric with the synthetic resin or the like.

  In the double-sided circular knitted fabric, the ratio of the multiple knit stitches to the total stitches is preferably in the range of 20% to 100% on the surface having the multiple knit stitches. In a double-sided circular knitted fabric, when the ratio of multiple knit stitches is 20% or more, the thickness of the double-sided circular knitted fabric can be easily obtained.

  The upper limit of the preferable range of the ratio of the multiple knit stitches is 100%. That is, all the stitches may be multiple knit stitches. Conventionally, there has been a circular knitted fabric formed with multiple knit stitches, but the double-sided circular knitted fabric of the present embodiment has (N-1) or less yarns among multiple knitted stitches composed of N yarns. The rib yarns are connected by tuck stitches, and the meaning is completely different from the conventional multiple knit stitches.

  Furthermore, the ratio of the multiple knit stitches to the total stitches is more preferably 25% or more and 50% or less. When the ratio of the multiple knit stitches is in the range of 25% to 50%, the productivity is further improved.

  Long and / or short fibers are used for the double-sided circular knitted fabric, and conventionally known fibers such as natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers can be used as the types of fibers. Particularly preferably, synthetic fibers are used. As the synthetic fiber, a synthetic fiber multifilament yarn is preferably used, and among the synthetic fibers, a polyester fiber or a polyamide fiber having high strength is preferably used. Further, by using a synthetic fiber multifilament yarn as the surface layer yarn, the tensile strength and tear strength can be increased.

  Synthetic fiber multifilament yarns include raw yarns that are straight yarns that have not been subjected to higher-order yarn processing after the yarn-making process, false-twisted yarns that have been subjected to higher-order yarn processing, air-mixed yarns, air entanglement Yarn etc. are used. In particular, when emphasizing thickness (feeling of swelling), false twisted yarn is preferably used.

  The cross-sectional shape of the fiber is not particularly limited, and may be not only a normal round shape but also a flat shape, a triangular shape, a hollow shape, a Y shape, a T shape, a U shape, and the like.

  The average fineness of the knitting yarn forming the surface layer is preferably in the range of 15 to 350 dtex. If the average fineness is smaller than 15 dtex, the tensile strength and tear strength are poor, and if it is thicker than 350 dtex, the composite fabric becomes heavy. In particular, when the composite fabric according to the present embodiment is used as a synthetic leather for a sheet such as an automobile or furniture, the average fineness of the knitting yarn forming the surface layer is preferably 70 to 250 dtex.

  Furthermore, when the bulkiness of the double-sided circular knitted fabric is required, it is preferable that the fineness of the rib yarn is two-fifth or more of the average fineness of the yarn that does not catch the tack stitch among the knitting yarns forming the surface layer. . As for the stitches of the double-sided circular knitted fabric of the present embodiment, the rib yarn is looser than the knitting yarn forming the surface layer. For this reason, the ratio of the rib yarn contributing to the thickness is high, and the bulkiness is easily obtained.

  However, if the fineness of the rib yarn is 5 times or more the average fineness of the knitting yarn forming the surface layer, the surface layer is likely to be uneven, and the appearance quality of the resin layer is impaired. Moreover, when using a synthetic fiber multifilament thread for a rib thread | yarn, it is preferable that a single fiber fineness exists in the range of 0.3-4 dtex. The thicker the single fiber fineness of the rib yarn, the easier the thickness is to come out. However, if it exceeds 4 dtex, the fabric becomes too hard, and if it is less than 0.3 dtex, the thickness becomes difficult to come out.

  The double-sided circular knitted fabric according to the present embodiment can be subjected to final adjustment of the number of wells and the number of courses in the dyeing process after being knitted by adapting the knitting machine and knitting conditions to desired conditions, etc. Finished to the desired knitting density. The knitting machine is not particularly limited as long as it is a double circular knitting machine, but in order to obtain the desired knitting density, a double circular knitting machine of 18 gauge or more is preferable, and it is more preferably 20 gauge or more.

  A conventionally known dyeing method can be used as the dyeing method for the double-sided circular knitted fabric. In addition, incidental processing at the dyeing stage includes water repellent processing, antifouling processing, water absorption processing, antibacterial processing, deodorization processing, deodorization processing, flame retardant processing, and the like. These incidental processes are preferably given as appropriate according to the intended purpose.

  Furthermore, it is preferable that the double-sided circular knitted fabric according to the present embodiment uses an original yarn (raw solution colored fiber) at least partially and is not dyed. By making the dyeing process unnecessary by using the original yarn, the environmental load can be reduced. Moreover, a composite fabric excellent in dyeing fastness can be obtained. As the original yarn, polyester fiber, nylon fiber, acrylic fiber, or the like is preferably used.

  The double-sided circular knitted fabric preferably has a tensile strength measured based on a measurement method specified in JIS of 300 N or more and a tensile elongation of 70% or more. If the tensile elongation is 70% or more, it has sufficient stretchability and can follow complicated shapes. Moreover, it is preferable that the tear strength measured based on the measuring method prescribed | regulated to JIS is 40N or more. When the tear strength is 40 N or more, it becomes a strong synthetic leather that is not easily torn for use in seats for automobiles and furniture.

  The double-sided circular knitted fabric of the composite fabric preferably has one surface raised. By raising one side of the double-sided circular knitted fabric, a bulky fabric is obtained. In particular, since the surface that is not a multi-knit stitch is in a state in which the yarn is likely to be excessive, raising the thickness easily results in a bulky fabric.

  On the other hand, regarding the double-sided circular knitted fabric of the composite fabric, it is also preferable that the surface is not brushed. Since the composite fabric according to the present embodiment has a bulky double-sided circular knitted fabric, it is already a sufficiently bulky fabric even in a state where it is not brushed. Therefore, the raising process can be omitted, and the manufacturing can be facilitated and the manufacturing cost can be reduced. Moreover, the unevenness of the thickness which arises in a raising process product does not occur easily, and the problem that the fluff yarn raised during use is crushed and becomes thin is less likely to occur.

Sided circular knitted fabric that one side is not brushed machining is preferably bulkiness is 3.50cm ³ / g or more, more preferably 4.00 cm ³ / g or more, more preferably 4.20cm ³ / g or more. When the bulkiness of the double-sided circular knitted fabric is 3.50 cm ³ / g or more, a fabric that can feel a light weight can be obtained. The upper limit of bulkiness is about 15.00 cm ³ / g.

  As the synthetic resin in the composite fabric according to the present embodiment, a known polymer compound can be used. For example, polyolefin, polystyrene, polyvinyl, polyacryl, polyhaloolefin, polydiene, polyether, polysulfide, polyester, polyamide, polyurethane, polyurea, polyimide, polyanhydride, polycarbonate, polyimine, polysiloxane, polyphosphazene, polyketone, Examples include regular and irregular homopolymers and copolymers such as polysulfone and polyphenylene. Furthermore, biodegradable resins such as polyamino acid resins and polylactic acid resins, and polymer alloys such as copolymers and mixtures of the above-described synthetic resins are also included. It is also possible to use resins having different thermal behaviors such as thermoplastic resins and thermosetting resins.

  Synthetic resins can be used according to their purpose, but applications such as tensile properties, shear properties, bending properties, compression properties, creep properties, thermal properties, impact resistance, hardness, heat resistance, combustion properties, etc. From the viewpoint of physical properties and weather resistance such as light resistance, chemical resistance, and abrasion resistance, a polyurethane resin, a copolymer thereof, or a mixed resin containing polyurethane resin as a main component is preferable. Further, the synthetic resin can be used for forming the synthetic resin layer in any form such as aqueous, solvent-based, solvent-free, and hot-melt type.

  In the polyurethane resin, if necessary, within a range that does not impair the properties of the polyurethane resin, a urethane curing agent, a urethanization catalyst, a crosslinking agent, a silane coupling agent, a filler, a thixotropic agent, a tackifier, a wax, Heat stabilizer, light resistance stabilizer, fluorescent whitening agent, thermoplastic resin, thermosetting resin, dye, pigment, flame retardant, conductivity imparting agent, antistatic agent, moisture permeability improver, water repellent, oil repellent, Hollow foam, crystal water-containing compound, water-absorbing agent, moisture-absorbing agent, deodorant, foam stabilizer, anti-foaming agent, antifungal agent, antiseptic, algaeproofing agent, pigment dispersant, inert gas, anti-blocking agent, Arbitrary components, such as a hydrolysis inhibitor, can be used individually by 1 type or in combination of 2 or more types.

  The synthetic leather made of the composite fabric according to the present embodiment may be manufactured by either a wet method or a dry method. The wet method here refers to a double-sided circular knitted fabric coated with a synthetic resin dissolved in a solvent at a predetermined concentration, solidified in a coagulation bath containing a poor solvent, and a lot in the form of a sponge in the synthetic resin layer. In this method, the fine communication holes are formed, followed by washing with water and drying steps to obtain a product. That is, a coating layer is formed on a double-sided circular knitted fabric.

  Also, there are two types of dry methods. One is the application of a synthetic resin dissolved in a solvent at a predetermined concentration on a double-sided circular knitted fabric by a known coating method such as knife-on-roll coating or roll-on-roll coating. And a direct coating method in which the solvent is volatilized in a dryer and solidified. That is, a coating layer is formed on a double-sided circular knitted fabric. The other is to apply a resin to a releasable substrate such as a release paper by a known coating method and dry it to form a skin layer, and apply an adhesive on this skin layer by a known coating method, It is a method of bonding and drying with a knitted fabric and thermocompression to make a product. That is, a laminate layer is formed on a double-sided circular knitted fabric.

  As the synthetic resin used as the adhesive, a known polymer compound can be used. In particular, it is preferable to select a polyurethane resin, a copolymer thereof, or a mixed resin mainly composed of a polyurethane resin from the viewpoint of a resin that does not impair the tactile sensation and has a friction durability due to adhesion and physical load. Among these, a polycarbonate-based polyurethane resin and a two-component wet-curable hot-melt resin crosslinked with an isocyanate compound is preferable.

  As a method for forming the adhesive layer, conventionally known methods can be used. For example, it can be formed by applying on a double-sided circular knitted fabric using a technique such as spray coating or gravure coating.

  It is also possible to form an adhesive layer by a method in which an adhesive is applied on a releasable substrate and a double-sided circular knit fabric is adhered, and then the releasable substrate is peeled off. Here, the releasable base material is not particularly limited, and a film composed of a release agent such as a resin (for example, olefin resin, silicone resin, fluororesin) having releasability with respect to polyurethane resin, Examples include release paper, release cloth, and release film in which a release layer composed of a mold agent is laminated on a base material such as paper, fabric, and film. The releasable base material may have a concavo-convex pattern, and by using such a releasable base material, design properties can be imparted to the surface of the synthetic leather.

  The form of the adhesive layer is preferably a state with few voids from the viewpoint of friction durability, and preferably has a thickness of 20 μm to 300 μm, and more preferably 50 μm to 150 μm from the viewpoint of texture. When it is thinner than 20 μm, there is a possibility that sufficient friction durability as synthetic leather cannot be obtained, and when it is thicker than 300 μm, there is a possibility that a soft and elastic tactile sensation close to natural leather cannot be obtained.

  As a method for applying the polyurethane resin composition to the releasable substrate, various methods conventionally known to those skilled in the art can be employed, and the method is not particularly limited. For example, the method using apparatuses, such as a reverse roll coater, a spray coater, a roll coater, a gravure coater, a kiss roll coater, a knife coater, a comma coater, a T-die coater, can be mentioned. Among these, application with a knife coater or a comma coater is preferable in that a uniform thin film layer can be formed.

  Next, heat treatment is performed as necessary. The heat treatment accelerates the reaction when the solvent in the polyurethane resin composition is evaporated and the resin is dried, and when a crosslinking agent that causes a crosslinking reaction by the heat treatment is used, or when a two-component curable resin is used. And is performed to form a film having sufficient strength. It is preferable that the heat processing temperature is 50-150 degreeC, More preferably, it is 60-120 degreeC.

  If the heat treatment temperature is less than 50 ° C., the heat treatment takes time, and there is a possibility that the process load becomes large, or the crosslinking of the resin is insufficient and the wear resistance becomes poor. If the heat treatment temperature exceeds 150 ° C., the texture of the synthetic leather may become coarse and hard. The heat treatment time is preferably 2 to 20 minutes, more preferably 3 to 10 minutes. If the heat treatment time is less than 2 minutes, the resin may not be sufficiently crosslinked, resulting in poor wear resistance. If the heat treatment time exceeds 20 minutes, the processing speed may become slow and the process load may increase.

  Next, embodiments of the composite fabric according to the present invention will be described more specifically with reference to the drawings.

  FIG. 1 is a perspective view schematically showing a composite fabric according to an embodiment of the present invention. As shown in FIG. 1, a composite fabric 10 according to the present embodiment includes a double-sided circular knitted fabric 11 as a fibrous base material and a synthetic resin layer 12 provided on the surface thereof. The synthetic resin layer 12 is a coating layer, a laminate layer, or a layer in which a laminate layer is further doubled on the coating layer.

  FIG. 2 is a cross-sectional view schematically showing a II cross section of the composite fabric 10 according to the present embodiment. As shown in FIG. 2, the composite fabric 10 has multiple knit stitches that form the same stitch with two yarns, and has a rib yarn connected to one of the two yarns with a tack stitch. The surface of the double-sided circular knitted fabric 11 having a configuration has a cross-sectional structure in which a synthetic resin layer 12 is applied with a predetermined thickness.

  Hereinafter, examples of the composite fabric according to the present invention will be described in detail. However, the following examples are for explaining the present invention more specifically, and do not limit the present invention.

  First, a double-sided circular knitted fabric that is a fibrous base material of a composite fabric according to an example of the present invention and a method for manufacturing the double-sided circular knitted fabric will be described as examples. In addition, each physical-property value in an Example was measured with the following method.

(1) Weight per unit
Based on JIS L 1096 8.4.2, the mass (g / m ² ) per unit area of the test piece was measured.

(2) Thickness
The thickness of the test piece was measured based on JIS L 1096 8.5.1. For the measurement, a dial thickness gauge (“Model H-10” manufactured by Ozaki Mfg. Co., Ltd.) was used.

(3) Bulkiness
Based on the basis weight value measured by the method (1) and the thickness measured by the method (2), the bulkiness of the test piece was calculated according to the following formula.
K = H / M × 1000
K: Bulkiness (cm ³ / g)
H: Thickness (mm)
M: basis weight (g / m ² )

(4) Tensile strength and tensile elongation
Based on JIS L 1096 8.12.1 A method (strip method), the tensile strength (N) and tensile elongation (%) of the test piece were measured. However, the test piece was measured with a width of 3 cm and a length of 30 cm.

(5) Tear strength
The tear strength (N) of the test piece was measured based on JIS K 6772 7.5.

[Example 1]
As shown in FIG. 1, a composite fabric 10 according to Example 1 of the present invention includes a double-sided circular knitted fabric 11 as a fibrous base material and a laminate layer as a synthetic resin layer 12 provided on the surface thereof. It is configured. The double-sided circular knitted fabric 11 constituting the composite fabric 10 according to Example 1 has a stitch structure shown in FIG. The double-sided circular knitted fabric according to Example 2 described later also has the same stitch structure as that of Example 1.

  As shown in FIG. 3, the double-sided circular knitted fabric 11 according to the first embodiment includes a rib yarn 14 and knitting yarns 15 and 16. In the double-sided circular knitted fabric 11, the knitting yarn 15 forms a knitted stitch at the needle positions a1 to a8, the knitting yarn 16 forms a knitted stitch at the needle positions a1, a3, a5, and a7, a knitted stitch 17 and a double knitted stitch 18 It has a structure that contains. Further, the rib yarn 14 has a structure in which a knit stitch is formed at the needle positions b1 to b7, a tack stitch 19 is formed at the needle positions a1, a3, a5, and a7, and the tack stitch 19 is caught only by the yarn 16. . In the first embodiment, the rib yarn 14 is a polyester 84 dtex, 36 filament false twist yarn, the knitting yarn 15 is a polyester 167 dtex, 48 filament false twist yarn, the knitting yarn 16 is a polyester 33 dtex, 12 filament temporary yarn. Twisted yarn was used.

These rib yarns 14 and knitting yarns 15 and 16 were fed to a 22 gauge double circular knitting machine, and the double-sided circular knitted fabric 11 shown in FIG. Furthermore, the knitting yarn 15 forms a knitted stitch at the needle positions a1 to a8, the knitting yarn 16 forms a knitted stitch at the needle positions a2, a4, a6, and a8, and the stitches corresponding to the knitted stitch 17 and the double knitted stitch 18 The rib yarn 14 formed one course having the knit stitches at the needle positions b1 to b7 and the tack stitch corresponding to the tack stitch 19 at the needle positions a2, a4, a6, and a8. A total of two courses were combined to form a double-sided circular knitted fabric of one complete knitting structure. The fabric thus obtained was scoured, dyed and heat-set according to a normal dyeing method to obtain a knitted fabric having a basis weight of 269 g / m ² .

  Thus, since the double-sided circular knitted fabric constituting the composite fabric according to the first embodiment is a double knit knitted fabric, the thickness can be easily obtained. Moreover, since it is a double knit knitted fabric, it will also be excellent in strength as a fabric. Table 1 shows the results of evaluating the physical property values of the above (1) to (5) for the double-sided circular knitted fabric according to Example 1.

  A composite fabric according to Example 1 was manufactured by laminating a synthetic resin on a double-sided circular knitted fabric having such characteristics.

  First, a dimethylformamide-toluene solution of a polycarbonate-based polyurethane resin was applied on a squeezed release paper with a knife coater so that the thickness after drying was 30 μm, and dried at 100 ° C. to form a skin layer. Furthermore, a dimethylformamide-toluene solution of a two-component polycarbonate resin was applied to the surface of the skin layer with a knife coater so that the thickness after drying was 70 μm, and dried at 100 ° C.

  A double-sided circular knitted fabric was pasted on this, left in a state of being wound up at 40 ° C. for 48 hours, and then the release paper was peeled off to obtain a composite fabric having a thickness of 1.42 mm. Table 2 shows a comprehensive evaluation of the composite fabric according to Example 1 obtained in this way, together with the evaluation results of various properties of the double-sided circular knit fabric in Table 1.

  Since the composite fabric according to Example 1 has the above-described structure, it has excellent characteristics as shown in Tables 1 and 2. Thereby, the composite fabric which concerns on the present Example 1 is used as a synthetic leather lightweight and excellent in cushioning properties. In addition, by appropriately setting properties such as the material, thickness, structure, and porosity of the laminate layer, the composite fabric is given moisture and water repellency and water repellency, so that it can be used for fabrics such as sports clothing. Can also be applied.

[Example 2]
In the double-sided circular knitted fabric 11 according to Example 2 of the present invention, a false twisted yarn of polyester 84 dtex and 36 filaments, which is colored black by kneading carbon black in the spinning process as the rib yarn 14, was used. Further, as the knitting yarn 15 and the knitting yarn 16, false twisted yarn of polyester 167 dtex, 48 filaments kneaded with carbon black in a spinning process and colored in black was used.

These rib yarns 14 and knitting yarns 15 and 16 were fed to a 20-gauge double circular knitting machine to form a double-sided circular knitted fabric 11 shown in FIG. The fabric thus obtained was scoured, dyed and heat-set according to a normal dyeing method to obtain a knitted fabric having a basis weight of 285 g / m ² .

  Next, lamination processing with a polycarbonate-based polyurethane resin was performed in the same manner as in Example 1 to obtain a composite fabric having a thickness of 1.30 mm. Table 1 and Table 2 show the results and comprehensive evaluation of various properties of the composite fabric according to Example 2 obtained in this way.

  On the other hand, in order to compare the properties with those of the composite fabrics according to Examples 1 and 2, the composite fabrics of Comparative Examples 1 and 2 were produced as follows.

(Comparative Example 1)
Similar to Example 1, the composite fabric of Comparative Example 1 also has a structure corresponding to the composite fabric 10 according to the above embodiment. However, in Comparative Example 1, the structure of the double-sided circular knitted fabric as the fibrous base material of the composite fabric is different.

  FIG. 4 is a schematic diagram showing a schematic cross section of a double-sided circular knitted fabric 110 used in Comparative Example 1. As shown in FIG. 4, the double-sided circular knitted fabric 110 of Comparative Example 1 is composed of knitting yarns 111 and 112 and a rib yarn 113, and has a knitted stitch 114, a double knitted stitch 115, and a knitted stitch 116. doing. The knitting yarn 112 and the rib yarn 113 are double knit stitches 115 at the needle positions c1, c3, c5 and c7, the rib yarn 113 is the knit stitch 114 at the needle positions d2, d4, d6 and d8, and the knitting yarn 111 is the needle position. A knit stitch 116 is formed by d1, d3, d5, and d7.

  In Comparative Example 1, as the knitting yarns 111 and 112 and the rib yarn 113, a false twisted yarn of polyester 84 dtex and 36 filaments was used. These knitting yarns 111 and 112 and the rib yarn 113 were fed to a 28 gauge double circular knitting machine, and the double-sided circular knitted fabric 110 shown in FIG. Further, the knitting yarn 112 and the rib yarn 113 are knitted stitches corresponding to the double knitting stitch 115 at the needle positions c2, c4, c6, and c8, and the rib yarn 113 is knitted stitch 114 at the needle positions d1, d3, d5, and d7. Corresponding knit stitches, one course in which the knitting yarn 111 has knit stitches corresponding to the knit stitches 116 at the needle positions d2, d4, d6, and d8 was formed. These two courses knitted a double-sided circular knitted fabric with one complete knitting structure.

  Here, as shown in FIG. 4, in the double-sided circular knitted fabric 110 of Comparative Example 1, the knitting yarn 112 and the rib yarn 113 form double knit stitches 115 at all the needle positions c1, c3, c5, and c7. Yes. However, the double-sided circular knitted fabric 110 is one in which the knitting yarn 112 and the rib yarn 113 form a multi-knit stitch. N-1) It does not satisfy the requirement that “the rib yarn is connected to the following yarns with tuck stitches”.

  Therefore, the structure of Comparative Example 1 is different from the structure of the double-sided circular knitted fabric according to the present invention, and according to claim 2 of the present invention, “the ratio of multiple knit stitches to all stitches is in the range of 20% to 100%. It does not mean that the requirement “inside” is satisfied. Therefore, as shown in Table 1, the ratio of the multiple knit stitches in Comparative Example 1 is 0%.

The fabric thus obtained was scoured, dyed and heat-set according to a normal dyeing method to obtain a knitted fabric having a basis weight of 236 g / m ² . Next, laminating with a polycarbonate-based polyurethane resin was performed in the same manner as in Example 1 to obtain a composite fabric 10 having a thickness of 0.84 mm. Table 1 and Table 2 show the results and comprehensive evaluation of various properties of the composite fabric of Comparative Example 1 obtained as described above.

(Comparative Example 2)
Unlike Examples 1 and 2 and Comparative Example 1, the double-sided circular knitted fabric constituting the composite fabric of Comparative Example 2 does not have multiple knit stitches. That is, as shown in Table 1, the ratio of multiple knit stitches in the double-sided circular knitted fabric of Comparative Example 2 is 0%.

  FIG. 5 is a schematic diagram showing a schematic cross section of a double-sided circular knitted fabric 120 of Comparative Example 2. As shown in FIG. 5, the double-sided circular knitted fabric 120 of Comparative Example 2 is composed of a rib yarn 121 and a knitting yarn 123. The knitting yarn 123 forms a knit stitch 125 at the needle positions e1 to e8, and only the knit stitch 125 has a structure. Further, the rib yarn 121 has a structure in which a knit stitch is formed at the needle positions f1 to f7, a tack stitch 126 is formed at the needle positions e1, e3, e5, and e7, and the tack stitch 126 is caught by the knitting yarn 123. .

  In Comparative Example 2, polyester 167 dtex, 48 filament false twisted yarn was used as the knitting yarn 123, and polyester 84 dtex, 36 filament false twisted yarn was used as the rib yarn 121. These rib yarn 121 and knitting yarn 123 were fed to a 22 gauge double circular knitting machine, and the double-sided circular knitted fabric 120 shown in FIG. Further, the knitting yarn 123 forms a knit stitch corresponding to the knit stitch 125 at the needle positions e1 to e8, the rib yarn 121 forms the knit stitch at the needle positions f1 to f7, and the tack stitch at the needle positions e2, e4, e6, e8. Tack stitches corresponding to 126 were formed. A double-sided circular knitted fabric having a honeycomb structure with one complete knitting structure was knitted with these two courses in total.

The fabric thus obtained was scoured, dyed and heat-set according to a normal dyeing method to obtain a knitted fabric having a basis weight of 258 g / m ² . Next, laminating with a polycarbonate polyurethane resin was performed in the same manner as in Example 1 to obtain a composite fabric having a thickness of 1.11 mm. Table 1 and Table 2 show the results and overall evaluation of various properties of the composite fabric of Comparative Example 2 obtained as described above.

As shown in Table 1, in Examples 1 and 2, the double stitch ratio of the double-sided circular knitted fabric is 50%, the basis weight is less than 300 g / m ² , and it has a sufficient thickness and bulkiness. ing. And since tensile strength and tensile elongation are large and it is excellent in elasticity, it has the characteristic of following a complicated three-dimensional shape and suitable as an interior material. Therefore, as shown in Tables 1 and 2, the composite fabrics according to Examples 1 and 2 are lightweight, thick and have excellent cushioning properties and strength, and are suitable for synthetic leather.

  Further, in Examples 1 and 2, by appropriately selecting the type and structure of the synthetic resin as the composite material constituting the laminate layer, the composite fabric is imparted with characteristics such as moisture permeable waterproofness, water repellency, and air permeability. be able to. As described above, the composite fabric according to Examples 1 and 2 is particularly suitable as a cloth for sports clothing because it is lightweight and excellent in stretchability. Therefore, it can be applied as a high-value-added composite fabric for clothing by imparting properties such as moisture permeability and waterproofness, water repellency, and air permeability.

  In addition, as described in the above embodiment, the composite fabric according to the present invention is not limited to the one in which the laminate layer is formed, the coating layer is formed on the double-sided circular knitted fabric, and the double-sided circular knitted fabric is impregnated with the synthetic resin. By forming a coating layer on top or forming a composite fabric with a coating layer formed and a laminate layer formed on it, there are more options for imparting characteristics suitable for sports apparel fabrics and a wide range of applications. It becomes possible.

  As mentioned above, although embodiment and Example of this invention were described, this invention is not limited by said embodiment and Example.

  That is, various embodiments and modifications can be made to the present invention without departing from the broad spirit and scope of the present invention. The embodiments and examples described above are for explaining the present invention and do not limit the scope of the present invention.

  Since the composite fabric according to the present invention uses a double-sided circular knitted fabric having a unique structure as a fibrous base material, it is lightweight, bulky and has cushioning and strength. It can be used as an excellent and suitable synthetic leather. Furthermore, the present invention can be applied to lightweight clothing having characteristics such as moisture permeability and waterproofness.

10 Composite fabric
11, 110, 120 Double-sided circular knitted fabric
12 Layer of synthetic resin
14, 113, 121 Rib yarn
15, 16, 111, 112, 123 Knitting yarn 17, 114, 116, 125 Knit stitch 18, 115 Double knit stitch
19, 126 Tuck stitch
a1, a2, a3, a4, a5, a6, a7, a8, b1, b2, b3, b4, b5, b6, b7, c1, c2, c3, c4, c5, c6, c7, c8, d1, d2, d3, d4, d5, d6, d7, d8, e1, e2, e3, e4, e5, e6, e7, e8, f1, f2, f3, f4, f5, f6, f7 Needle position

Claims (5)

A composite fabric comprising a double-sided circular knitted fabric knitted using long fibers and / or short fibers,
The double-sided circular knitted fabric includes multiple knit stitches that form the same stitch with N yarns (N ≧ 2), and one or more of the N yarns that form the multiple knit stitches, (N-1) A composite fabric comprising rib yarns connected to the following yarns and tuck stitches, and the double-sided circular knitted fabric being coated and / or laminated and / or impregnated with a synthetic resin .   2. The composite fabric according to claim 1, wherein in the surface having the multiple knit stitches, a ratio of the multiple knit stitches to all stitches is within a range of 20% to 100%.   The composite fabric according to claim 1 or 2, wherein an original yarn is used for at least a part of the double-sided circular knitted fabric, and the double-sided circular knitted fabric is not dyed.   The composite fabric according to any one of claims 1 to 3, wherein one side of the double-sided circular knitted fabric is brushed. The composite fabric according to any one of claims 1 to 3, wherein a surface of the double-sided circular knitted fabric is not brushed.

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