JP4328986B2 - Elastic fabric and cushioning material with excellent cushioning and sag resistance - Google Patents

Description

【００３６】
【表２】

【００３７】
【表３】

【００３８】
実施例および比較例の結果より次のことが確認される。すなわち、実施例1〜3は、緯糸に融点の異なる2種類のポリエーテルエステル系弾性糸を、他方経糸にポリエステル糸を用い、乾熱処理を行なって目止めを行なった織物であり、伸長後の弾性回復量が良好であり、かつ優れた弾性があり、また、滑脱抵抗力があり、ほつれ・目ずれがなく、着座感も優れることからクッション材に必要な特性をすべて満足する織物であった。
【００３９】
比較例1は、ポリエーテルエステル系弾性糸を使用しない織物であり、伸長後の回復量がほとんどなく、弾性を示さなかった。
比較例2は、ポリエーテルエステル系弾性糸を1種類しか使用しない織物であり、滑脱抵抗力がなく、ほつれ・目ずれをおこしていた。
比較例3は、ポリエーテルエステル系弾性糸を2種類使用しているが、乾熱処理を行なっていない織物であり、溶融・再固化による目止めがされておらず、滑脱抵抗力がなく、ほつれ・目ずれをおこしていた。
比較例で作成したこれらの織物はいずれも、クッション材としては、好ましくないものであった。
【００４０】
【発明の効果】
本発明によると、目ずれをせずに優れた弾性と弾性回復性を示し、クッション材として好適な弾性織物を提供することを可能とした。
【図面の簡単な説明】
【図１】本発明にかかる織物の組織図の一例。
【図２】実施例１、３および比較例３で使用した織物の組織図。
【図３】実施例１〜３の熱処理後の織物における接着固化成分の状態を示す模式図。
【図４】実施例２で使用した織物の組織図。
【図５】比較例２で使用した織物の組織図。
【図６】比較例４で使用した織物の組織図。
【図７】比較例４の熱処理後の織物における接着固化成分の状態を示す模式図。
【符号の説明】
Ａ：高融点弾性糸、
Ｂ：低融点弾性糸、
Ｃ：芯鞘構造弾性糸（芯＝高融点のポリエーテルエステル樹脂、鞘＝低融点のポリエーテルエステル樹脂を使用）。
１：経糸、２：低融点ポリエ−テルエステル樹脂、３：緯糸。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an elastic woven fabric and a cushioning material which are excellent in cushioning properties and sag resistance when subjected to repeated deformation, and are particularly suitable for furniture and office chairs.
[0002]
[Prior art]
Conventionally, urethane foam, polyester fiber-filled cotton, resin cotton bonded with polyester fiber, solid cotton, and the like are used for cushion materials for furniture and beds. In order to obtain comfortable performance as a cushion, many are devised such as composites of different cushioning properties or a double structure at the time of cushion molding. All of these cushion materials have a problem that they are bulky or cannot obtain a cushion with a small volume.
[0003]
From this point of view, development of a material that saves space and has excellent cushioning properties is desired.
[0004]
[Problems to be solved by the invention]
An object of the present invention is to provide an elastic fabric, particularly an elastic fabric for a sheet that is excellent in cushioning and sag resistance and can be used as a cushioning material in a space-saving manner.
[0005]
[Means for Solving the Problems]
That is, according to the first aspect of the present invention, a low melting point polyether ester fiber resin is obtained by heat-treating a fabric in which a polyether ester monofilament elastic yarn having two or more single structures having different melting points is arranged on warp and / or weft. It is an elastic woven fabric excellent in cushioning and settling resistance, characterized by having the following physical properties fused and solidified at the intersection of the woven warp and weft .
(1) History The stress at 10% elongation in any one direction is 20-50kg / 5cm
(2) The breaking strength in the warp direction and the weft direction of the fabric is 25 kgf / 5 cm width or more.
(3) The slip resistance of the elastic yarn of the fabric is 0.2 kgf or more.
The second invention of the present invention is a cushioning material having excellent cushioning properties and anti-sagging properties, characterized by using the elastic fabric according to the first invention.
Specifically, the elastic woven fabric having the cushioning property and the anti-slip property described above, in which either a warp or a weft is a polyether ester-based elastic yarn, and the other is a polyester yarn, and the elastic yarn is contained in the woven fabric. The above-described ratio is characterized in that the content of the elastic fabric excellent in cushioning properties and sag resistance, and the low melting point elastic yarn in the fabric is 2 to 60 wt%. An elastic woven fabric excellent in cushioning properties and set resistance, and an elastic woven fabric excellent in cushioning properties and set resistance as described above, wherein the elastic yarn is a monofilament.
The present invention is described in detail below.
[0006]
The cushion material as used in the field of this invention is components used for the various uses using cushion performance, The utilization method is not specifically limited. For example, it can be used on the seat and / or back of an office chair and can be used alone to provide a cushioning function. The cushioning material is urethane foam, polyester fiber-filled cotton, resin cotton or solid cotton bonded with polyester fiber, springs, etc. Can be used as a part of the chair structure. Moreover, it can also be used combining another fabric which gave the design property to the surface layer.
[0007]
Specific uses of the elastic fabric and the cushion material include, for example, use in office chairs, living chairs, and seats for transportation equipment such as automobiles and trains, but the present invention is not limited to these.
[0008]
The polyether ester elastic yarn used in the present invention is not particularly limited, but an aromatic dicarboxylic acid and a glycol are used as main raw materials in order to obtain strength necessary for a sheet fabric, recovery after elongation, and the like. Aromatic polyesters are preferred. Furthermore, a polyester elastic yarn obtained by copolymerizing polybutylene terephthalate and polytetramethylene glycol is more preferable because it has good recoverability after elongation.
[0009]
It is necessary to use a polyetherester-based elastic yarn in at least one of the weft directions of the fabric according to the present invention. By using a polyether ester-based elastic yarn, the recoverability after elongation is kept good.
[0010]
As the elastic yarn according to the present invention, at least two kinds of elastic yarns having different melting points are used. By performing heat treatment, the elastic yarn having a low melting point is melted while maintaining the elastic modulus of the elastic yarn having a high melting point. This is because it becomes possible to re-solidify and to check the intersection of the fabrics. In addition, when at least two kinds of elastic yarns having different melting points are heat-treated, the low melting point polyetherester fiber resin is fused while being unevenly distributed at the intersection of the warp and weft of the fabric, so that the strength of the fabric, the elastic recovery rate, etc. A strong sealing property can be obtained without lowering. In addition, it is possible to effectively seal only by using a small amount of a low-melting-point polyetherester resin.
[0011]
An elastic yarn having a low melting point can use a yarn having a melting point of 100 ° C. or higher due to spinnability and weaving, and 30 ° C. or lower than the melting point of an elastic yarn having a high melting point depending on the intended use of the elastic yarn. Further, the use ratio of the elastic yarn having a high melting point and the elastic yarn having a lower melting point can be arbitrarily selected, but is practically preferably 1: 1 to 20: 1 by weight. More preferably, it is 3: 2 to 15: 1. Further, the heat treatment is preferably performed at a temperature between 10 ° C. lower than the melting point of the elastic yarn having a higher melting point and 10 ° C. higher than the melting point of the elastic yarn having a lower melting point. By heat-treating this woven fabric, it is possible to sufficiently bond it with other yarns that are in contact with the fabric structure. Needless to say, the melting point of the polyester yarn used in this fabric must be equal to or higher than that of the polyether ester elastic yarn having a high melting point.
[0012]
In the present invention, it is desirable that the elastic yarn having the highest melting point and the elastic yarn having the lower melting point used for sealing the same have the same ups and downs as a structure in the woven fabric. An example of such a structure using elastic yarns as wefts is shown in FIG. Alternatively, it is desirable to use both in advance or by twisting them together. Thereby, when an elastic yarn having a lower melting point is melted, a good sealing property can be obtained for an elastic yarn having a high melting point that retains elasticity and other yarn that remains without being melted. The elastic yarn constituting the woven fabric may be used in either direction of warp or weft, but it is preferable to use it for the weft from the viewpoint of weaving property and quality of the fabric.
[0013]
The use ratio of the elastic yarn having the highest melting point and the elastic yarn having the lower melting point in the present invention can be arbitrarily selected, but is practically preferably 3: 1 to 1: 2 in terms of the number of yarns. More preferably, it is 2: 1 or 1: 1.
[0014]
The elastic yarn according to the present invention is more preferably a monofilament. Even if it is a multifilament, there is no problem in mechanical properties such as recoverability after stretching, but it may be inferior in durability because of its low resistance to friction. The fineness of the preferred monofilament is 100 denier or more and 6000 denier or less. If it is less than 100 denier, there is little resistance to friction and durability may not be sufficiently obtained, and if it exceeds 6000 denier, handling in textile production becomes difficult. A more preferable range of fineness is not less than 300 denier and not more than 3000 denier. In addition, multifilaments with a single yarn of 100 denier or more can be used.
[0015]
The polyester yarn used in the woven fabric according to the present invention may be an unprocessed one, a loop processed yarn or a false twisted yarn, or a mixture of both. The yarn can be an original yarn or a pre-dyed yarn. The use of polyester yarn is preferable because all yarns constituting the woven fabric are polyester-based and can be easily recycled.
[0016]
The slip resistance of the polyether ester elastic yarn in the woven fabric according to the present invention is an important physical property as a cushion material for a seat. This value must be greater than 0.2kgf. If the sliding resistance is less than 0.2 kgf, misalignment or fraying occurs, which is not preferable. More preferably, the slip resistance is 0.5 kgf or more, even more preferably 1 kgf or more, and further 2 kgf or more.
[0017]
The warp strength in the warp direction and the weft direction of the fabric according to the present invention is also an important physical property as a cushion material for a seat. This value must be at least 25kgf / 5cm wide. If the breaking strength is less than 25 kgf / 5 cm width, the fabric may break due to the load applied to the surface during use as a cushioning material, which is not preferable. More preferably, it is 35 kgf / 5 cm width or more, more preferably 50 kgf / 5 cm width or more, and further 80 kgf / 5 cm width or more.
[0018]
The stress at 10% elongation in at least one direction of the woven fabric according to the present invention must be 20 kg / 5 cm or more and 50 kg / 5 cm or less. If it is less than 20kg / 5cm, the amount of sinking when used as a cushioning material is large, and uncomfortable feelings occur especially when seated as a seat. On the other hand, if it is larger than 50kg / 5cm, the amount of sinking as a seat will be too small and pain will occur when sitting, so it will not withstand long-term use.
[0019]
Further, the recovery rate after elongation in the direction of using the elastic yarn is desirably 95% or more. The recovery rate after extension here is measured as follows. First, the upper end of the fabric is fixed, an initial load is applied to the lower end so that the fabric does not loosen, and marks are made at intervals of 50 cm. A load is applied to the lower end of the fabric so that the length of the fabric is 55 cm, and the fabric is left as it is for 24 hours. The length between the marks on the fabric after being left for 24 hours is measured, and this is designated L1. Next, after removing the load and leaving it to stand for 3 hours, the initial load is applied again, and the length between the marks of the fabric after the release of the load after stretching is measured, and this is defined as L2. Using the numerical values thus obtained, ((L1-L2) / (L1-50)) * 100 (%) is taken as the recovery rate after elongation. If the recovery rate after elongation is less than 95%, when this fabric is used as a cushioning material for supporting the buttocks of the seat, it is not preferable because once the seat is seated, the fabric remains in a relaxed state.
[0020]
If it is necessary to impart flame retardancy and light resistance to the woven fabric according to the present invention, a yarn containing a flame retardant and a light resistant agent may be used, or a flame retardant and a light resistant agent may be imparted to the fabric. Can do. As for elastic yarn, a method of adding melamine cyanurate or imparting a phosphorus compound as a flame retardant as a material mixed with a raw material resin is known, but is not particularly limited thereto. Moreover, although the light-resistant prescription by addition of carbon black etc. is used also as a light-resistant agent, it is not specifically limited to this.
[0021]
If it is necessary to impart color to the elastic yarn used in the fabric according to the present invention, a dye or a pigment may be contained. As the pigment, a method of adding an inorganic pigment such as a phthalocyanine-based organic pigment, carbon black, titanium oxide, or zinc oxide is known, but is not particularly limited thereto. By using the original yarn containing the pigment, the labor of dyeing can be saved.
[0022]
【Example】
The present invention will be described below based on examples. The present invention is not particularly limited by the examples. In addition, the measuring method used in the Example is as follows.
[0023]
(Strength of raw yarn) Based on JIS L 1013, measurement was performed using a constant speed extension type testing machine at a grip interval of 100 mm and a tensile speed of 100 mm / min.
[0024]
(Strength of fabric and stress at 10% elongation) Based on JIS L 1096, measurement was performed using a constant-speed elongation type testing machine at a grip interval of 200 mm, a test piece width of 50 mm, and a tensile speed of 100 mm / min.
[0025]
(Subsidence amount, recovery amount after stretching) A 65cm weight with a 40cm square iron frame fixed in a horizontal plane, chamfered with a bottom of 20cm x 10cm and a radius of 5mm on each edge, and elastic yarn In the case of the containing woven fabric, it was placed on the central portion of the woven fabric so that the long side was parallel to the elastic yarn, and was allowed to stand for 24 hours. The position in the vertical direction of the fabric surface before loading was used as a base point, and the difference from the position of the fabric surface when left under load for 24 hours was determined as the amount of subsidence of the fabric. After the amount of sinking was measured, the weight applied to the fabric surface was removed and left for 3 hours. The position in the vertical direction of the fabric surface when left for 24 hours was used as a base point, and the difference from the position of the fabric surface after leaving for 3 hours after removing the weight was determined as the recovery amount after elongation of the fabric.
[0026]
(Fraying = Seamability) Based on JIS L 1096, the sliding resistance by the thread drawing method A was measured. Using a constant-speed extension type testing machine, measurement was performed at a grip interval of 30 mm, a sample piece width of 20 mm, and a tensile speed of 30 mm / min.
[0027]
(Sitting feeling) The fabric was fixed to a 40 cm square iron frame in a horizontal plane, and the feeling was examined by sitting on the upper part.
[0028]
Example 1
A density of 1500d polyetherester monofilament elastic yarn with a melting point of 222 ° C as weft and 500d polyetherester monofilament elastic yarn with a melting point of 182 ° C in total of 40 yarns / inch, and a density of 28 yarns / inch of 750d polyester multifilament yarns as warp A woven fabric having the woven structure shown in FIG. 2 and having A as the 1500d polyetherester monofilament elastic yarn and B as the 500d polyetherester monofilament elastic yarn was prepared. This fabric was subjected to a dry heat treatment at 200 ° C. for 3 minutes.
As shown in FIG. 3, it was confirmed that the low-melting-point polyetherester resin was unevenly distributed and adhered and solidified at the intersection of the warp and weft of the fabric as shown in FIG. 3.
In addition, the seating feeling of the sample after the heat treatment was very good, and it was sufficiently usable as a cushioning material for seats on office chairs, living chairs, cars, trains, and the like. Table 1 shows the physical properties and performance of yarns and fabrics. The reason why the weft density of the woven fabric is decreased after the dry heat treatment is that the low melting point fibers of the polyetherester monofilament are melted and not counted in the density because the dry heat treatment is performed.
[0029]
(Example 2)
A 1500d polyetherester monofilament elastic yarn with a melting point of 222 ° C and a 500d polyetherester monofilament elastic yarn with a melting point of 182 ° C, including two 1500d monofilament elastic yarns and one 500d monofilament elastic yarn as a weft, for a total of 30 yarns / inch, warp yarn 640d polyester multifilament yarn fluid turbulence processed multifilament loop yarn with a density of 28 / inch and a woven structure shown in Fig. 4, A is 1500d polyetherester monofilament elastic yarn, A fabric was prepared using B as a 500d polyetherester monofilament elastic yarn. This fabric was subjected to a dry heat treatment at 200 ° C. for 3 minutes. It was confirmed that the state of the adhesive solidifying component of the fabric after heat treatment was unevenly distributed at the intersection of the warp and weft of the fabric as in Example 1. In addition, the seating feeling of the sample after the heat treatment was very good, and it was sufficiently usable as a cushioning material for seats on office chairs, living chairs, cars, trains, and the like. Table 1 shows the physical properties and performance of yarns and fabrics. The reason why the weft density of the woven fabric is decreased after the dry heat treatment is that the low melting point fibers of the polyetherester monofilament are melted and not counted in the density because the dry heat treatment is performed.
[0030]
(Example 3)
1500d polyetherester monofilament elastic yarn colored with carbon black with a melting point of 218 ° C and 500d polyetherester monofilament elastic yarn colored with a carbon black with a melting point of 172 ° C. It has the woven structure shown in Fig. 2 with a density of 28 / inch of 1500d polyester multifilament yarn colored in black, A is colored 1500d polyetherester monofilament elastic yarn, B is colored 500d polyetherester monofilament elasticity A woven fabric was created. The fabric was heat treated at 190 ° C. for 2.5 minutes. It was confirmed that the state of the adhesive solidifying component of the fabric after heat treatment was unevenly distributed at the intersection of the warp and weft of the fabric as in Example 1. In addition, the seating feeling of the sample after the heat treatment was very good, and it was sufficiently usable as a cushioning material for seats on office chairs, living chairs, cars, trains, and the like. Table 1 shows the physical properties and performance of yarns and fabrics. The reason why the weft density of the woven fabric is decreased after the dry heat treatment is that the low melting point fibers of the polyetherester monofilament are melted and not counted in the density because the dry heat treatment is performed.
[0031]
(Comparative Example 1)
A 1000d polyester yarn was used for both warp and weft, and a plain weave with a warp density and a weft density of 27 / inch was prepared. The seating feeling is very hard and unsuitable as a cushioning material for seats on office chairs, living chairs, cars and trains. Table 2 shows the physical properties and performance of yarns and fabrics.
[0032]
(Comparative Example 2)
A woven fabric having a woven structure shown in FIG. 5 was prepared in which a 1500d polyetherester monofilament elastic yarn having a melting point of 222 ° C. was used as the weft and the density was 20 / inch, and the 750d polyester multifilament yarn was 28 / inch in the warp. The fabric was heat treated at 200 ° C. for 3 minutes. Although the seating feeling was good, the woven fabric after seating was vacant and close to the fabric, and was unsuitable as a seat cushion material for office chairs, living chairs, cars and trains. Table 2 shows the physical properties and performance of yarns and fabrics.
[0033]
(Comparative Example 3)
A 1500d polyetherester monofilament elastic yarn with a melting point of 222 ° C and a 500d polyetherester monofilament elastic yarn with a melting point of 182 ° C are alternately wefts for a total of 40 yarns / inch, and 750d polyester multifilament yarns for warp yarns of 28 yarns / inch A woven fabric having the woven structure shown in FIG. 2 in density, with A as the 1500d polyetherester monofilament elastic yarn and B as the 500d polyetherester monofilament elastic yarn was prepared. Although the seating feeling was good, the woven fabric after seating was vacant and close to the fabric, and was unsuitable as a seat cushion material for office chairs, living chairs, cars and trains. Table 2 shows the physical properties and performance of yarns and fabrics.
[0034]
(Comparative Example 4)
A monofilament having a core-sheath structure in which a polyether ester resin having a melting point of 222 ° C. is used for the weft and a polyether ester resin having a melting point of 162 ° C. is used for the sheath, and the total weight is 2000d at a weight ratio of core: sheath = 80: 20. A woven fabric having a woven structure shown in FIG. 6 was prepared with a density of 20 yarns / inch for elastic yarns and a density of 28 yarns / inch for 750d polyester multifilament yarns as warp yarns. This fabric was subjected to a dry heat treatment at 190 ° C. for 2.5 minutes.
As shown in FIG. 7, it was confirmed that the low-melting-point polyether ester resin was uniformly bonded and solidified over the entire wefts of the fabric as shown in FIG.
In addition, the seating feeling of the sample after heat treatment was good, but the fabric after sitting was vacant and close, and as a seat cushion material for office chairs, living chairs, cars, trains, etc. , Found to be inappropriate.
[0035]
[Table 1]

[0036]
[Table 2]

[0037]
[Table 3]

[0038]
The following is confirmed from the results of Examples and Comparative Examples. That is, Examples 1 to 3 are woven fabrics in which two types of polyetherester elastic yarns having different melting points are used for the weft yarns and polyester yarns are used for the other warp yarns, which are subjected to dry heat treatment and sealed. It was a woven fabric that satisfied all the characteristics required for cushioning materials because of its good elastic recovery, excellent elasticity, resistance to slipping, no fraying and misalignment, and excellent seating feeling. .
[0039]
Comparative Example 1 is a woven fabric that does not use a polyetherester elastic yarn, has little recovery after stretching, and does not exhibit elasticity.
Comparative Example 2 is a woven fabric that uses only one type of polyetherester elastic yarn, has no slip-off resistance, and frays and misaligns.
Comparative Example 3 is a woven fabric that uses two types of polyetherester elastic yarns but has not been dry-heat treated, is not sealed by melting and re-solidifying, has no slip-off resistance, and frays.・ I was misaligned.
Any of these woven fabrics prepared in the comparative examples was not preferable as a cushioning material.
[0040]
【The invention's effect】
According to the present invention, it is possible to provide an elastic fabric that exhibits excellent elasticity and elastic recovery without causing misalignment and is suitable as a cushioning material.
[Brief description of the drawings]
FIG. 1 is an example of a structure diagram of a fabric according to the present invention.
FIG. 2 is a structure diagram of a fabric used in Examples 1 and 3 and Comparative Example 3.
FIG. 3 is a schematic diagram showing a state of an adhesive solidifying component in the woven fabric after heat treatment in Examples 1 to 3.
FIG. 4 is a structural diagram of a fabric used in Example 2.
FIG. 5 is a structural diagram of a fabric used in Comparative Example 2.
6 is a structural diagram of the fabric used in Comparative Example 4. FIG.
7 is a schematic diagram showing a state of an adhesive solidifying component in a fabric after heat treatment in Comparative Example 4. FIG.
[Explanation of symbols]
A: high melting point elastic yarn,
B: low melting point elastic yarn,
C: Core-sheath elastic yarn (core = high melting point polyether ester resin, sheath = low melting point polyether ester resin).
1: warp, 2: low melting point polyester ester resin, 3: weft.

Claims (5)

A low melting point polyetherester fiber resin is melted at the intersection of the warp and weft of the fabric by heat treatment of the fabric in which the polyetherester monofilament elastic yarn having two or more single structures with different melting points is arranged on the warp and / or the weft. An elastic woven fabric having excellent cushioning properties and sag resistance, characterized by having the following physical properties after solidification .
(1) History The stress at 10% elongation in any one direction is 20-50kg / 5cm
(2) The breaking strength in the warp direction and the weft direction of the fabric is 25 kgf / 5 cm width or more.
(3) The slip resistance of the elastic yarn of the fabric is 0.2 kgf or more. The elastic woven fabric excellent in cushioning properties and sag resistance according to claim 1, wherein either a warp or a weft is a polyetherester-based elastic yarn and the other is a polyester yarn. The elastic fabric excellent in cushioning properties and sag resistance according to claim 1, wherein the content of the elastic yarn in the fabric is 25 wt% or more. 2. The elastic fabric excellent in cushioning and settling resistance according to claim 1, wherein the content of the low melting point elastic yarn in the fabric is 2 to 60 wt%. A cushioning material excellent in cushioning properties and sag resistance, characterized by using the elastic fabric according to claim 1.

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