JP4749757B2 - Cushion material - Google Patents

Description

  The present invention relates to a technique for preventing monofilaments from jumping out from a cover material used for an edge in a cushion material using a three-dimensional knitted fabric and facilitating sewing of the cover material.

Conventionally, a three-dimensional knitted fabric has both high breathability and cushioning properties, and therefore has been used as a breathable cushion material in place of foamed polyurethane for seat materials such as vehicle seats and furniture, as well as cushions and bedding materials.
For example, in Patent Document 1, a three-dimensional knitted fabric expressed as a three-layer structure three-dimensional fabric, a backing material such as a cloth / non-woven fabric, a batting, and a backing fabric are laminated, these are integrally quilted, and the outer periphery is further laminated. What is edge-sewn with an edge cover material is disclosed.
If this product is used with the three-dimensional knitted fabric in the upper part, that is, the side in contact with the human body at bedtime, a good sleep can be obtained.

However, when used as a bedding material in this way, for example, even if it is specified that the outer periphery is sewed with an edge cover material, no physical properties of the edge cover material have been studied. Usually, when a three-dimensional knitted fabric is used as a bedding material, a monofilament having a single yarn fineness of about 15 to 1500 decitex is used for the yarn constituting the front and back knitted surfaces and the connecting yarn connecting the front and back knitted surfaces to exhibit cushioning properties. Generally, it is used as a single yarn, a twisted yarn made up of a plurality of monofilaments, or a composite of monofilaments and multifilaments.
In such a case, since the monofilament is very rigid, the monofilament penetrates through the outer peripheral edge portion and reaches the body portion when used, irritate the skin, and in extreme cases, penetrates the skin and causes puncture.
Even when used as a seat for furniture or a car seat, there are similar problems when seated.
Japanese Utility Model Publication No. 06-022283

  An object of the present invention is to provide a cushioning material that prevents the connecting thread from penetrating from the edge cover material even when sleeping and sitting as a bedding material, a furniture seat, or a car seat material, and that has excellent sewing properties. To do.

The present inventor is a cushioning material that prevents a monofilament from penetrating from the edge cover material even when sitting and sitting on a bedding material, furniture seat, or car seat material using a three-dimensional knitted fabric, and has good sewing work. As a result of intensive studies, the present invention has been completed.
That is, the present invention
(1) One or a plurality of three-dimensional knitted fabrics knitted from yarns constituting the front and back knitted surfaces and connecting yarns including monofilaments having a single yarn fineness of 15 to 1500 dtex for connecting the front and back knitted surfaces and / or A cushion material obtained by sewing the outer periphery of a cushion material composed of a combination of a three-dimensional knitted fabric and other materials with an edge cover material, and piercing the edge cover material with a sewing needle (TV × 7 # 19 manufactured by Organ Co., Ltd.) A cushioning material characterized by using an edge cover material having a strength F of 0.5 to 20 N;
(2) The cushioning material according to 1 above, wherein the ventilation resistance of the edge cover material is 0.1 to 150 kPa · sec / m,
(3) The monofilament protrusion value represented by the ratio (F / D) of the sewing needle piercing strength F of the edge cover material to the monofilament diameter D of the three-dimensional knitted fabric is 9 to 50 N / mm Or the cushion material according to 2,
(4) The cushion material according to any one of the above items 1 to 3, wherein the edge cover material is subjected to a crushing process by calendering,
(5) The cushion material according to any one of the above 1 to 4, wherein the edge cover material is subjected to resin processing on at least one side thereof,
It is.

  INDUSTRIAL APPLICABILITY The present invention has an effect of preventing the connecting thread from penetrating from the edge cover material even when sleeping and sitting as a bedding material, a furniture seat, or a car seat material, and having excellent sewing properties.

Hereinafter, the present invention will be described in more detail.
The three-dimensional knitted fabric provided for the cushion material of the present invention is composed of front and back knitted fabrics and connecting yarns for connecting the front and back knitted fabrics. The three-dimensional knitted fabric can be knitted by a double raschel machine having two rows of needles, a double circular knitting machine or the like. The front and back knitted fabrics are not particularly limited, and it is preferable to use a knitted fabric having a plurality of openings such as a mesh knitted fabric, a margitette knitted fabric and the like because air permeability is improved. The front and back knitted fabrics may be the same knitted structure or different structures.
The type of fiber used for the front and back knitted surfaces of the three-dimensional knitted fabric is not particularly limited. For example, synthetic fibers such as polyester, polyamide and polyacrylonitrile, regenerated cellulose fibers such as cupra and rayon, wool, cotton Natural fibers and the like. In addition, the cross-sectional shape of the fiber is round, triangular, L-shaped, T-shaped, Y-shaped, W-shaped, four-leaf type, eight-leaf type, flat, dog-bone type, etc., multi-leaf type, It may be hollow or irregular.

  The connecting yarn that connects the front and back knitted surfaces of the three-dimensional knitted fabric does not limit the fiber type, single yarn fineness, cross-sectional shape, etc., but at least the single yarn fineness of the synthetic fiber monofilament alone, the monofilament twisted yarn body or 15 to 1500 dtex It is preferably a composite of monofilament and multifilament, more preferably 15 to 1500 dtex monofilament is preferably used in order to maintain the space between the front and back knitted surfaces of the three-dimensional knitted fabric, and it is breathable. And has the effect of excellent cushioning. Further, if the single yarn fineness of the connecting yarn is less than 15 dtex, the bending rigidity of the fiber is small, so that it is difficult to maintain the space between the front and back knitted surfaces of the three-dimensional knitted fabric, and the air permeability and the cushioning property are impaired. In addition, when the single yarn fineness of the connecting yarn exceeds 1500 dtex, the bending rigidity is too large and it becomes difficult to knit the three-dimensional knitted fabric.

The thickness of the three-dimensional knitted fabric is preferably in the range of 1.5 to 20 mm. If the thickness is less than 1.5 mm, sufficient air permeability and cushioning properties cannot be obtained, and if the thickness exceeds 20 mm, the productivity of the knitted fabric is poor. Therefore, the cost increases.
Other materials to be combined with the three-dimensional knitted fabric include natural cotton, synthetic fiber cotton, or a combination of these fibers, as well as cotton obtained by appropriately compressing these fiber cottons and applying a synthetic resin to these cottons to improve compression recovery. Improved or foams such as polyurethane foam, polyethylene foam, polystyrene foam, etc., and combinations of these foams with cotton, or fibers made of thermoplastic resin or thermoplastic elastic resin are irregular. Examples thereof include a three-dimensional structure having a thickness of about 5 to 50 mm that forms a contact that is entangled and contacted by entanglement. Moreover, in order to integrate them with a three-dimensional knitted fabric, a cotton cloth, a synthetic fiber cloth, etc. may be used.

  The inventor is a cushion material obtained by sewing the outer periphery of a cushion material formed by combining one or a plurality of three-dimensional knitted fabrics and / or a three-dimensional knitted fabric and another material with an edge cover material. And it discovered that the sewing needle of the edge cover material (TV × 7 # 19 manufactured by Organ Co., Ltd.) had a great correlation with the protrusion of the monofilament from the cushion material, and the present invention was achieved.

That is, in the present invention, a cushion material obtained by sewing one or more solid knitted fabrics and / or an outer periphery of a cushion material formed by combining a solid knitted fabric and another material with an edge cover material, The edge cover material sewing needle (TV × 7 # 19, manufactured by Organ Co., Ltd.) must have a piercing strength F of 0.5 to 20N.
When the piercing strength of the sewing machine needle is less than 0.5N, the monofilament used for the connecting thread of the three-dimensional knitted fabric on the cushioning material when sitting or sleeping will easily penetrate the edge cover material and reach the body part, Causes skin irritation and, in extreme cases, can penetrate the skin and cause puncture.

In addition, when the piercing strength of the sewing machine needle exceeds 20N, the bending strength of the edge cover material becomes too hard, making it difficult to perform sewing work, making it difficult to pierce the sewing machine at the time of sewing, and placing a burden on the sewing machine, Normal sewing is difficult. In addition, problems such as an increased risk of the sewing machine being broken during the sewing operation occur.
The sewing needle piercing strength F is preferably 1.5 to 10N, and more preferably 2 to 10N.

The edge cover material to be used selects the material fineness and the density of the woven or knitted fabric so that the airflow resistance is in an appropriate range, and the piercing strength of the sewing needle (TV × 7 # 19 manufactured by Organ Co., Ltd.) is in the range of 0.5 to 20N. Can be adjusted. At this time, the ventilation resistance R of the edge cover material is preferably 0.1 to 150 kPa · sec / m, and more preferably 0.3 to 130 kPa · sec / m.
Whether or not the edge cover material can suppress the extrusion of the monofilament is highly related to the diameter of the monofilament, and the monofilament extrusion expressed by the ratio (F / D) of the sewing needle piercing strength F to the monofilament diameter D A value of 9 to 50 N / mm is preferred because the monofilament protrusion prevention property is higher. More preferably, it is 16-40 N / mm.

The edge cover material is preferably crushed by calendering in order to further prevent monofilament penetration, and synthetic resin such as polyurethane or polyacrylonitrile is coated or dipped on one or both sides. More preferably, it is processed.
The fiber material used for the edge cover material is not particularly limited, and may be synthetic fiber, regenerated cellulose fiber, natural fiber, or a composite fiber thereof. Further, the fineness of the fiber is not limited.
Further, the edge cover material does not limit the density of the woven fabric, the knitted fabric, and the density thereof, and a material that is slit narrowly for the edge cover material may be a straight cut or a bias cut.

Hereinafter, the present invention will be described more specifically with reference to examples and the like.
The measuring method used in the present invention is as follows.
(1) Method of measuring the piercing strength of the sewing needle With the sewing needle (TV × 7 # 19 manufactured by Organ Co., Ltd.) attached to the chuck of Tensilon and the edge cover material fixed to a circular pin frame with a diameter of 30 mm, the sewing needle Is pierced at a speed of 50 mm / min, and the maximum stress during penetration is measured. The measurement is repeated three times from the front and back sides of the edge cover material, and the average value is obtained.
(2) Ventilation Resistance of Edge Cover Material The ventilation resistance R (kPa · sec / m) of the edge cover material is measured using a KES-F8-AP1 air permeability tester manufactured by Kato Tech Co., Ltd. In addition, the measurement measures three places of an edge cover material, and calculates | requires an average value.

(3) Method for evaluating presence or absence of monofilament protrusion (a) Prepare samples for evaluation (size 40 cm × 40 cm) described later for each of three levels.
(B) When one sample for evaluation of (a) is placed on an office chair and the total time sitting on it exceeds 20 hours, the monofilament penetrating the edge cover material Observe for presence.
(C) Evaluation of (b) is carried out by three subjects, subjects A, B, and C, with different levels and samples. In addition, the test subject's body weight was selected from the person of the range of 50-80 kg, and the test subject A was 58 kg, the test subject B was 65 kg, and the test subject C was 74 kg.
(D) The overall evaluation is “Yes” when two or more monofilaments are found out of three subjects, and “No” when the number is one or less.

(Reference Example 1)
[3D knitting]
Three-dimensional knitted fabric A: Uses an 18-gauge double raschel machine with a 5.6mm gap between 6 hooks and supplies 200dtex nylon 6 monofilament yarn as a connecting thread from two hooks (L3, L4) located in the middle Then, 167 dtex / 48f polyethylene terephthalate multifilament yarn is used as the surface knitted fabric yarn from the two folds (L1, L2) located on the front surface of the knitting machine, and the two folds (L5, L6) located on the back surface of the knitting machine. ), A 167 dtex / 48f polyethylene terephthalate multifilament yarn was supplied in an array of 1 in 1 out to the L1, L4, and L5 guides, and 1 out 1 in to the L2, L3, and L6. The setting was set at 20.7 course / 2.5 cm to obtain a three-dimensional knitted fabric of front and back meshes of the knitting structure shown below.
The obtained three-dimensional knitted fabric was scoured at 70 ° C. and then subjected to tentering heat setting (180 ° C.). The obtained three-dimensional knitted fabric had a thickness of 4.0 mm, 27.0 course / 2.5 cm, and 13.0 wale / 2.5 cm.

(Knitting organization)
L1: 4644/4244/4644/4244/4644/4222 /
2022/2422/2022/2422/2022/2444 /
L2: 2022/2422/2022/2422/2022/2444 /
4644/4244/4644/4244/4644/4222 /
L3: 6868/6464/6868/2020/6868/6464 /
4242/4646/4242/8108 1010/4242/4646 /
L4: 4242/4646/4424/810810/4242/4646 /
6868/6464/6868/2020/6868/6464 /
L5: 4446/4442/4446/4442/4446/4442 /
2220/2224/2220/2224/2220/2224 /
L6: 2220/2224/2220/2224/2220/2224 /
4446/4442/4446/4442/4446/4442 /

  Solid knitted fabric B: Supplying 56 dtex nylon 6 monofilament yarn as connecting yarn from two rivets (L3, L4) located in the middle using a 22 gauge double raschel machine equipped with 5 heels 110 dtex / 60f polyethylene terephthalate multifilament atypical cross section yarn (Technofine (registered trademark), manufactured by Asahi Kasei Co., Ltd.) as two yarns (L1, L2) located at the front of the knitting machine As a yarn for the back knitted fabric from a single ridge (L5) located on the back side of the knitting machine, a 110 dtex / 36f polyethylene terephthalate multifilament yarn is 2 in 2 out in the L1 and L3 guides, The L2 and L4 guides were supplied in a 2-out 2-in array and the L5 guide was supplied in an all-in array. With a setting of 33.0 courses / 2.5 cm for driving, a three-dimensional knitted fabric of front and back meshes of the following knitting structure was obtained.

  The obtained three-dimensional knitted fabric is scoured at 70 ° C., then heated for tentering (180 ° C.), and further added to a 2% aqueous solution of a surfactant (Nicepol (registered trademark) PR-99, manufactured by Nikka Chemical Co., Ltd.) It was immersed and subjected to water absorption processing. The obtained three-dimensional knitted fabric had a thickness of 3.1 mm, 41.0 course / 2.5 cm, and 20.0 wale / 2.5 cm.

(Knitting organization)
L1: 2022/4644/2022/4666 /
81088/6466/81088/6444 /
L2: 81088/6466/81088/6444 /
2022/4644/2202/4666 /
L3: 2020/4646/2020/4646 /
810810/10464/810810/10464 /
L4: 810810/6464/881010/6464 /
2020/4646/2020/4646 /
L5: 2220/2224 /

  Three-dimensional knitted fabric C: Knitted and widened in the same manner as the three-dimensional knitted fabric B, except that 33 dtex polyethylene terephthalate monofilament yarn was used as the connecting yarn from the two reeds (L3, L4) located in the middle of the knitting machine. Heat set and water absorption processing were applied. The obtained three-dimensional knitted fabric had a thickness of 3.1 mm, 41.0 course / 2.5 cm, and 20 wale / 2.5 cm.

[Configuration of edge cover material]
PET taffeta a: 56 tex / 24f of polyethylene terephthalate multifilament is warp yarn, 84 dtex / 24f of polyethylene terephthalate multifilament is horizontal yarn, so that the density warp is 114 / 2.54cm, and the width is 82 / 2.54cm. Weaving and heat setting finished.

PET taffeta b: Polyethylene terephthalate multifilament 157dtex / 48f wooly yarn is used for warp and weft to weave and heat set to a density of 75 / 2.54cm, 61 / 2.54cm Finished.
PC blended plain fabric a: Plain fabric woven from 30/15 blended yarns of 65 wt% polyethylene terephthalate short fibers and 35 wet% cotton at a density of 114 / 2.54 cm in length and 73 in width / 2.54 cm.
PC mixed plain fabric b: A plain fabric obtained by weaving 30 count single yarns of 65 wt% polyethylene terephthalate short fibers and 35 wet% cotton at a density of 86 vertical / 2.54 cm and 61 horizontal / 2.54 cm.
PC mixed plain fabric c: A plain fabric obtained by weaving 30 count single yarns of 65 wt% polyethylene terephthalate short fibers and 35 wet% cotton at a density of 86 vertical / 2.54 cm and 50 horizontal / 2.54 cm.

[Example 1]
Using the three-dimensional knitted fabric A, the material was cut into a length of 40 cm and a width of 40 cm, and then sewn using an edge cover material having an outer periphery made of PET taffeta a. Three samples were prepared by this method, and it was observed whether or not the monofilament penetrated the edge cover material according to the evaluation method for the presence or absence of the monofilament protrusion. No penetration of the monofilament was observed.
The results are summarized in Table 1.

[Example 2]
A monofilament edge cover in the same manner as in Example 1 except that a PET taffeta b having a polyurethane resin dip-processed so as to be about 15 wt% is used as the outer peripheral edge cover material. The presence or absence of penetration from the material was observed. Monofilament penetration was not observed.
The results are summarized in Table 1.

[Example 3]
A monofilament edge cover in the same manner as in Example 1 except that the outer peripheral edge cover material is a PET taffeta b that is dip-processed so that the acrylic resin is about 15 wt% with respect to the fabric. The presence or absence of penetration from the material was observed. Monofilament penetration was not observed.
The results are summarized in Table 1.

[Example 4]
The PC mixed plain fabric a was calendered and used as an edge cover material. As the calendering conditions, a Verduin machine was used, a friction calendering with a cylinder speed ratio of 17: 1 was performed at a temperature of 190 ° C. and a pressure of 0.8 t / 2.54 cm.
When the presence or absence of penetration of the monofilament from the edge cover material was observed in the same manner as in Example 1, penetration of the monofilament was not observed.
The results are summarized in Table 1.

[Example 5]
After using 3D knitted fabric A and 3D knitted fabric B, cutting each into 40cm vertical x 40cm horizontal and then overlapping, the outer periphery was sewn using an edge cover material made by calendering PC mixed plain fabric a . Three samples were prepared by this method, and it was observed whether or not the monofilament penetrated the edge cover material according to the evaluation method for the presence or absence of the monofilament protrusion. No penetration of the monofilament was observed.
The results are summarized in Table 1.

[Example 6]
Except for superimposing the three-dimensional knitted fabric A and the three-dimensional knitted fabric C on the evaluation sample, the presence or absence of penetration from the edge cover material of the monofilament was observed in the same manner as in Example 5. Monofilament penetration was not observed.
The results are summarized in Table 1.

[Example 7]
Existence of penetration of the monofilament from the edge cover material was observed in the same manner as in Example 5 except that the three-dimensional knitted fabric A, cotton, and cotton sheets were superimposed on the evaluation sample. Monofilament penetration was not observed.
The results are summarized in Table 1.

[Example 8]
Existence of penetration of the monofilament from the edge cover material was observed in the same manner as in Example 1 except that the three-dimensional knitted fabric B was used and the PC mixed plain fabric a was used as the edge cover material. Monofilament penetration was not observed.
The results are summarized in Table 1.

[Example 9]
Existence of penetration of the monofilament from the edge cover material was observed in the same manner as in Example 8 except that the three-dimensional knitted fabric C was used and the PC mixed woven fabric b was used as the edge cover material. One subject saw some monofilament penetration, but two subjects did not see monofilament penetration.
The results are summarized in Table 1.

[Comparative Example 1]
Except for using the PC mixed plain fabric c, the presence or absence of penetration from the edge cover material of the monofilament was observed in the same manner as in Example 8. In two subjects, monofilament penetration was observed from several locations along the edge.
The results are summarized in Table 1.

[Comparative Example 2]
Except for using the PC mixed plain fabric c, the presence or absence of penetration from the edge cover material of the monofilament was observed in the same manner as in Example 1. In all subjects, monofilament penetration was observed from several locations along the edge.
The results are summarized in Table 1.

[Comparative Example 3]
Polyester fabric base fabric PVC-processed, but it was attempted to sew over the outer periphery of the three-dimensional knitted fabric A using an ester tarpaulin with 21N ester piercing strength as an edge cover material. .

According to the present invention, a bedding material using a three-dimensional knitted fabric, a seat for furniture, a sleeping material for an automobile seat material, a monofilament through the edge cover material even when seated, and a cushion material with good sewing work are obtained. be able to.

The cross-sectional schematic diagram of the front perspective view of Example 1 of this invention is shown. The cross-sectional schematic diagram of the front perspective view of Example 5 of the present invention is shown (a state in which a plurality of three-dimensional knitted fabrics are stacked and sewn with an edge cover material).

Explanation of symbols

1 Solid Knitting A
2 Surface knitting yarn of three-dimensional knitted fabric A (polyethylene terephthalate fiber)
3 Back knitting yarn of three-dimensional knitted fabric A (polyethylene terephthalate fiber)
4 Connecting thread of three-dimensional knitted fabric A (nylon monofilament)
5 Solid Knitting B
6 Front and back threads of 3D knitted fabric B (polyethylene terephthalate fiber)
7 Three-dimensional knitted fabric B connecting thread (nylon monofilament)

Claims (3)

A thickness knitted from a yarn constituting a front and back knitted surface having a plurality of openings and a connecting yarn containing at least 30 wt% or more of monofilaments having a single yarn fineness of 15 to 1500 dtex connecting the front and back knitted surfaces . A cushioning material obtained by sewing the outer periphery of a cushion material formed by combining one or a plurality of three-dimensional knitted fabrics of 5 to 20 mm and / or a three-dimensional knitted fabric and another material with an edge cover material, and the edge cover material Machine needle (TV × 7 # 19 manufactured by Organ Co., Ltd.) has a piercing strength F of 0.5 to 20 N , and the ventilation resistance of the edge cover material is 0.1 to 150 kPa · sec / m. monofilaments projecting value represented by the needle piercing the ratio of the monofilament diameter D of strong F and solid knitted fabric (F / D) is, that obtained by using the edge cover member is 9~50N / mm Cushion material, characterized.   The cushion material according to claim 1, wherein the edge cover material is subjected to a crushing process by a calendar process. The cushion material according to claim 1 or 2 , wherein the edge cover material is subjected to resin processing on at least one side.

Images