JP2508132B2 - Manufacturing method of monolithic contracted napped warp knitted fabric - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a stretchable napped warp knitted fabric having a cut pile, and particularly for integral molding suitable for automobile interiors, chair upholstery, etc. It is to provide a napped fabric.

(Prior Art) A knitted fabric used as an interior material for automobiles is laminated on a plastic sheet to form a composite sheet, which is then formed into a desired shape by press molding, thermoforming or vacuum forming. There is. Then, as such a fabric for integral molding, a napped warp knitted fabric consisting only of non-stretchable synthetic fiber yarns, a highly oriented undrawn yarn of synthetic fibers are arranged on the ground yarn and a part thereof, and the pile yarn is A napped warp knitted fabric on which another yarn is arranged and an elastic yarn having rubber-like elasticity as a part of the ground yarn, for example, a single needle bed as described in JP-A-58-49237. Non-stretch synthetic fiber yarns are laid on the front reed of the warp knitting machine and elastic yarns are laid on the back reed, respectively. Things are known.

(Problems to be solved by the invention) A napped warp knitted fabric made only of non-stretchable synthetic fiber yarns has a small elongation and a large cloth stress at the time of molding, which makes it difficult to form the desired shape. There was a problem that could not be obtained. In addition, a fabric using a highly oriented undrawn yarn of synthetic fiber as a part of the ground yarn constituting the ground structure is easy to form because the fabric stress decreases with the temperature rise in the molding at a high temperature of 130 ° C or higher. On the other hand, the pile yarn itself also undergoes heat treatment to change its napped state and texture, so that there has been a problem that the molding temperature and the use site are limited.

In addition, a non-stretchable yarn and an elastic yarn interwoven with each other are excellent in stretchability even at room temperature and have low cloth stress, but individual fibers forming naps are yarns that form a ground structure. Since it is obtained by raising the sinker loop of the strip, the height of the nap is restricted by the sinker loop, and it is necessary to lengthen the sinker loop to raise the nap. There is a problem that the elongation becomes small and the formability is lowered. In addition, since the non-stretchable yarn and the elastic yarn are interwoven, and the non-stretchable yarn is raised, the thickness and texture of the fabric are determined by the thickness of the non-stretchable yarn and the sinker loop length. When the height and density of the napped hair due to raising is increased, the elongation of the cloth is reduced, and it is not possible to freely determine the height, density and thickness of the cloth and the texture of the napped hair, and the stretchability becomes uneven. There was a problem of becoming.

This invention eliminates the above-mentioned drawbacks, and changes in the height and density of naps do not cause changes in the elongation of the fabric,
Easily molds due to low stress when stretching the fabric in the low temperature range from room temperature to 130 ° C, the height of the nap is large, and the elastic napped knitted fabric for integral molding with a high-quality feeling of moquette is efficiently used. A method for manufacturing is provided.

(Means for Solving the Problems) The method for manufacturing the stretchable napped warp knitted fabric for integral molding according to the present invention is a front reed and a reed of a two-needle warp knitting machine having three or more reeds. Each of them is supplied with a composite yarn of an elastic yarn and a crimped yarn as a ground yarn, and a synthetic fiber filament yarn is supplied as a pile yarn to the remaining middle reed, and is knitted with a front reed and a rear reed. The double warp knitted fabric in which the lining and the lining are joined together is knitted, and then the pile yarn is cut in the middle between the front fabric and the lining.

The warp knitting machine used in the present invention has three or more reeds and has a two-needle bed, and is usually called a double Russell machine, and its gauge is 16 to 32 gauge, particularly 18 to 28 gauge. Is preferred. Then, the above-described composite yarns are preferably arranged in a full set on each of the front and rear reeds, and all needles are knitted between two needles to knit into a Denby structure. The number of remaining reeds may be any number, and can be freely selected depending on the desired pattern, knitting structure, yarn usage, and the like.

The elastic yarn used for knitting the ground structure is a yarn having a rubber-like elasticity made of a synthetic elastomer, and a polyurethane elastomer, particularly an elastic yarn made of a polyether type or polyester type urethane elastomer is preferable. Further, the crimped yarn to be combined with the elastic yarn is one in which a polyester-based, polyamide-based, or the like multi-filament yarn is mechanically processed to impart crimps, and expands or contracts based on the crimps. Those having an expansion / contraction elongation ratio of 50% or more, especially false twisted yarn are preferable. The crimped yarn may be dyed yarn. The composite of the elastic yarn and the crimped yarn can be performed by covering, interlacing, mixed fiber, etc., but covering by winding the crimped yarn in a coil shape with the elastic yarn as a core is preferable. Further, the synthetic fiber filament yarn used as the pile yarn is a synthetic fiber multifilament yarn such as a polyester type, a polyamide type and a polyacrylic type and may or may not have crimps and has crimps. The textured yarn is preferably a false twist textured yarn or a Taslan textured yarn. Further, the pile yarn may be a dyed yarn or a dyed yarn, and those having different color tones and shades may be used in combination. The pile yarns are arranged according to the target pattern and nap density. However, whether the reeds are single or plural, as a whole, be arranged in a full set or more. Is desirable.

(Operation) According to the present invention, the pile yarn connecting the front and back fabrics is cut in the middle to form naps of the cut pile, so that the ground structure is composed of the composite yarn of the elastic yarn and the crimped yarn. , Two stretchable warp warp knitted fabrics whose cut piles are made of synthetic fiber filament yarns are knitted simultaneously. In this case, the height of the nap is determined by the distance between the front needle bed for knitting the outer material and the back needle bed for knitting the lining, and the height of the nap is adjusted by changing the distance between the front and rear needle beds. . And
By knitting the ground structure by the front reed and the ground structure by the rear reed into the same structure and moving the middle reed symmetrically in the longitudinal direction, two stretchable napped knitted fabrics of the same structure can be obtained. In addition,
The obtained knitted fabric is subjected to heat brushing, presetting, dyeing, finishing agent fix, finish setting and heat brushing in accordance with a conventional method to be a product, but when a dyed yarn or a spun yarn is used, The dyeing process is omitted. Also,
As a finishing agent, an antifouling agent, an antistatic agent, a softening agent or the like is applied by a mangle before finishing setting according to the use. Then, a plastic sheet is attached to the knitted fabric obtained by the above method to form a composite sheet, which is then formed into a desired shape by press molding, thermoforming, vacuum forming, or the like.

Since the above knitted fabric is composed of a composite yarn composed of an elastic yarn having a relatively large elongation and a crimped yarn having a relatively small elongation, the elongation of the entire knitted fabric is However, within the range where the crimp of the crimped yarn is stretched, the tensile modulus of the entire knitted fabric is low, and integral molding is easy, and the crimped yarn in the composite yarn is crimped. It develops and separates to fill the voids in the texture of the ground structure, and prevents exudation of the adhesive when it is bonded to a plastic sheet and integrally molded. When the crimp of the crimped yarn is fully stretched, the modulus of the knitted fabric rapidly rises, and the strength of the ground structure is maintained.

Then, as the elastic thread, a polyurethane elastic thread,
In particular, when a polyether type or polyester type urethane elastic yarn is used, the thermal stability of the warp knitted fabric is further improved, and the shape is stabilized by heat setting, and the elasticity is further improved. However, the fineness of the above elastic yarn is 20 to 14
0 denier, particularly 40 to 70 denier is preferable, and the preferable fineness of the filament constituting the elastic yarn is 8 to 20 denier, and the elastic yarn has a breaking elongation of 400% or more and a stress at 300% elongation. Is preferably 10 to 20 g. The fineness of the elastic yarn is less than 20 denier, or 30
When the stress at 0% elongation is less than 10 g, the stretching force is too low, the pile base is displaced when cutting the pile, and the pile height becomes uneven, and the density of the ground structure is reduced. It cannot be increased, and the fineness of the elastic thread is 14
If it exceeds 0 denier or the stress at 300% elongation exceeds 20 g, the stretching force of the composite yarn is too large to make loop formation during knitting difficult, and the tensile modulus of the ground structure, that is, the processing stress. Becomes too large, making integral molding difficult.

It is preferable to use a crimped yarn made of a polyester-based or polyamide-based synthetic fiber because it has excellent thermal fastness of crimp and various types of yarns having different denier or filament number can be obtained. . In particular, when a false twisted yarn of a polyamide synthetic fiber is used, it is more excellent in crimpability and bulkiness than the polyester type, so that the exudation of the adhesive is further reduced. However, the fineness of the multifilament yarn is preferably 30 to 140 denier, particularly preferably 50 to 100 denier, and if it is less than 30 denier, the effect of filling the voids of the stitch is small, and the strength of the ground structure is low, on the contrary, 140 denier. When it exceeds, the elongation stress of the fabric becomes too high, and it becomes difficult to obtain a desired shape at the time of molding, especially when the drawing degree is large, and it is necessary to increase the mixing ratio of the elastic yarns, which increases the production cost.

When the above elastic yarn and crimped yarn are combined by covering, the crimped yarn only needs to be wound around the elastic yarn in a tensioned state, and it is opened by electric force or aerodynamic force in other interlaced or mixed fibers. Since no fiber or entanglement is required, the compounding is performed easily and efficiently, and a uniform compound yarn having no unevenness along the length direction can be obtained, which is practical. However, the crimped yarn is wound into a coil with the elastic yarn stretched 3.0 to 4.0 times, and the number of turns is 300 to 800 per 1 m.
It is preferable to set the number of turns, particularly 400 to 600 times. When the number of windings is less than 300 times / m, the elastic yarn and the crimped yarn are partially separated, and the crimped yarn easily forms a loop. Catches on the knitting needle or thread guide and interferes with the knitting property.
When it exceeds 0 times / m, the composite property of the elastic yarn and the crimped yarn is good, but the crimped yarn itself is bundled, so that the crimping force and the bulkiness are lowered.

When crimped yarns such as false twisted yarns are used as the pile yarns, since these have bulkiness, it is possible to prevent the see-through in the stretched portion and the bent portion of the ground structure due to the molding. When the false twist textured yarn or the Taslan textured yarn is used, the phenomenon in which the napped portion collapses in one direction is further reduced due to the crimped shape. However, the fineness of the pile yarn is preferably 50 to 150 denier, and particularly preferably 70 to 100 denier.If it is less than 50 denier, the napped part lacks volume and the napped density becomes insufficient. Compressive force decreases. On the other hand, if it exceeds 150 denier, the napped part will be excellent in volume and density, but the fabric will be heavy, and the fabric will not shrink due to the stretching force of the composite yarn that forms the ground texture, for integral molding Unsuitable as a dough. In addition, when the fineness of the fibers forming the pile yarn is 0.5 to 5 denier, a preferable feeling is obtained.

(Example) A 4-knit, 28-gauge double Russell machine was used to knit the warp knitted fabric of the example shown in FIG. That is, the composite yarn 1 of the elastic yarn and the crimped yarn is arranged in a full set on the first reed (front reed) L ₁ and the front needle bed F causes the Denby structure (2
−1 / 1−1 / 0-1−1−1) ground texture is knitted, the first pile yarn 2a is arranged in a full set on the second reed (the first middle reed) L ₂ , and the front needle bed F And 0-1 / 0-1 / 2- while reciprocating the back needle bed B
Organizes 1 / 2-1 tissue, third reed (during the second reed) L ₃ to the second
Arrayed pile yarn 2b to full set, organized in the same tissue as the first pile yarn 2a, and further arranged the same composite yarn 1 and the first guide bar L ₁ to the full set of the fourth reed (rear reed) L _4, The same ground organization was organized.

The above-mentioned composite yarn 1 is obtained by stretching a polyether type urethane elastic yarn (70 denier, 7 filaments) 3.5 times into a core yarn, and using a nylon false twisted yarn (100 yarn) as a crimped yarn.
Denier, 20 filaments, expansion and contraction rate 65%) per 1m
It is formed by winding it into a coil with 500 turns.
It was warped with a draft of 60% and set on the double Russell machine. A polyester multifilament yarn (75 denier, 24 filament, bright yarn) was used as the first pile yarn 2a, and a cationic dyeable polyester multifilament yarn (75 denier, 24 filament) was used as the second pile yarn 2b. The number of courses on the machine is set to 54 courses / 2.54 cm, and the runner length of each yarn is 118 cm for the first reed L ₁ and the fourth reed L _4, and the second reed L ₂ and the third reed L ₃
Was set to 880 cm, and the front and rear needle bed spacing was set to 6 mm.

The double knitted fabric knitted under the above conditions is set on a dedicated center-cutting machine, and the first pile yarn 2a and the second pile yarn 2b are cut in the middle of the front and back knitted fabrics to form two elastic napped warp knitted fabrics. Got The height of the napped hair (cut pile) of this knitted fabric was 3 mm, showing a good appearance. Next, the above knitted fabric was heat-brushed (110 ° C x 20 seconds) and preset (dry heat 190
℃ × 30 seconds), one-bath dyeing with disperse dye (120 ℃ × 60
Min), finisher fix and final set (dry heat)
180 ° C. × 30 seconds) and thermal brushing (110 ° C. × 20 seconds) were performed in order to develop a shade-like and shade-like pattern due to the difference in dyeability of the first pile yarn 2a and the second pile yarn 2b.

On the other hand, using a 6 sheet reed, 22 gauge double Russell machine,
The warp knitted fabric of the comparative example shown in FIG. 2 was knitted. That is, the first reed (first front reed) L ₁ and the sixth reed (second rear reed) L ₆
Nylon false twisted yarns (70 denier, 17 filaments, elastic expansion / contraction rate 65%) 11 are arranged in a full set to knit the illustrated 1-0 / 3-4 structure, and the second reed (the second reed) ) Polyurethane elastic yarn (40 denier, 4 filaments) 12 is arranged in full sets on L ₂ and the 5th reed (the 1st rear reed) L ₅ to form the 1-2 / 1-0 structure shown in the drawing, and The 1st reed L ₁ and the 2nd reed L ₂ , and the 5th reed L ₅ and the 6th reed L ₆ form the ground structure of the reverse satin structure, respectively. In addition, the third pile (first middle reed) L ₃ and the fourth reed (second middle reed) L ₄ have the first pile yarn.
Two polyester multifilament yarns (100 denier, 30 filaments, semi-dal) as 13a and two cationic pile dyeable polyester multifilament yarns (100 denier, 36 filaments, bright) as second pile yarn 13b are alternately arranged. Full set on both sides,
The illustrated 8-course / repeat organization was organized. And
The number of courses on the machine is set to 50 courses / 2.54 cm, and the runner length of each yarn is 270 cm for the 1st reed L ₁ and 6th reed L ₆ and the 2nd reed L
₂ and 5 reed L ₅ to 80 cm, 3rd reed L ₃ and 4th reed L
₄ was set to 760 cm and the needle bed spacing was 5 mm.

The double knitted fabric knitted under the above conditions was cut by a dedicated center-cutting machine, dyed and finished as in the above-mentioned Examples.

The following tables show the properties and physical properties of the stretched warp warp knitted fabrics and the properties of the composite sheets of the above Examples and Comparative Examples. However, the elongation stress in the table was measured by the cut-slip method of JIS-L-1018. In addition, the composite sheet contains an adhesive composed of a two-component reactive urethane resin and a curing agent at a compounding ratio of 100 /
The mixture was mixed at 10, and this was applied to the above-mentioned finished fabric with a solid content of 30 μ, and a soft PVC resin film with a thickness of 0.45 mm was pressure-bonded and dried. And the obtained composite sheet
After heating to 120 ° C., it was molded using a vacuum molding type tester having a concave body having a degree of drawing of 0.5 and 0.7 (a circular depression having a diameter of 10 cm and a depth of 5 cm and 7 cm).

As is apparent from the above table, the examples of the present invention have a large density and a large basis weight as compared with the comparative examples in which another reed is knitted instead of compounding the elastic yarn and the crimped yarn. No significant difference in elongation stress and processing stress except when stretched by 30%, the stretch stress at 30% stretch is remarkably small, and the molded state and the appearance of the molded part are excellent, and there is no exudation of the adhesive.

(Effects of the Invention) Since the present invention uses a double Russell machine, the ground structure is composed of a composite yarn of elastic yarn and crimped yarn, and the cut pile is integrally formed with synthetic fiber filament yarn. It is possible to simultaneously produce two elastic napped warp knitted fabrics, and it is possible to easily set the napped height by adjusting the spacing of the needle beds. Therefore,
It is not necessary to nap, and therefore, unlike the napped product of a tricot knitted fabric, the ground yarn is not napped and the tissue is not disturbed, and by raising the nap, the stretchability is reduced and the integral moldability is lowered, In addition, by lowering the naps, the appearance and texture do not deteriorate.

And the elastic stretchable warp knitted fabric for integral molding obtained is
Since the ground structure is composed of the composite yarn of the elastic yarn and the crimped yarn, the tensile modulus of the knitted fabric is low within the stretch range of the crimped yarn, and the integral molding is easy and The expression of the crimp of the yarn fills the voids in the texture of the ground structure, and prevents the exudation of the adhesive during integral molding. Then, when the elongation limit of the crimped yarn is exceeded, the modulus of the knitted fabric increases and the strength of the knitted fabric is maintained.
Moreover, since the naps are formed by a synthetic fiber filament yarn different from the above-mentioned composite yarn, the height and density of the naps can be freely set independently of the ground texture, and the height of the naps can also be set. The elongation of the base structure is not limited by the density, and it is extremely excellent in moldability when it is integrally molded with a plastic sheet.

[Brief description of drawings]

FIG. 1 is an organization chart of an embodiment of the present invention, and FIG. 2 is an organization chart of a comparative example. 1: composite yarn, 2a, 2b: pile yarn, L ₁ : front reed, L ₂ , L ₃ : middle reed, L ₄ : rear reed, F: front needle bed, B: rear needle bed.

Claims (1)

(57) [Claims] 1. A composite yarn of an elastic yarn and a crimped yarn as a ground yarn is supplied to each of a front reed and a rear reed of a two-needle warp knitting machine having three or more reeds, and the remaining middle reed. Synthetic fiber filament yarn is supplied as a pile yarn to knit a double warp knitted fabric in which a front reed knitted surface and a back reed knitted lining are joined by the pile yarn, and then the outer material A method for manufacturing a stretchable napped knitted fabric for integral molding, characterized in that the pile yarn is cut between the lining and the lining.