JP4789577B2 - Molding method of three-dimensional solid knitted product - Google Patents

Description

The present invention relates to a method for forming a molded article using a three-dimensional solid knitted fabric.

Patent Documents 1 to 3 disclose a technique in which a three-dimensional solid knitted fabric (three-dimensional net material) is heat-compressed and processed into a brass cup or the like.
JP-A-9-31856 JP 2000-199104 A JP 2005-154998 A

  However, as disclosed in Patent Documents 1 to 3, when a three-dimensional solid knitted fabric is heated and compressed into a predetermined molded product, the three-dimensional solid knitted material constituting the molded product is compared with that before molding. As a result, the thickness becomes thinner and the compression recovery property deteriorates. In view of this point, in Patent Document 3, the compression recovery is improved by using a three-dimensional solid knitted fabric that has a special fabric characteristic as a processing target. The compression restoration property of the obtained molding is only about 50% with respect to the compression restoration property of the knitted fabric. In addition, the heat compression mold is expensive to manufacture and requires a long manufacturing period.

The present invention has been made in view of the above, and can be molded easily and molded with a three-dimensional solid knitted product that can be molded without lowering the thickness and compression recovery when compared with the three-dimensional solid knitted fabric before molding. It is an object to provide a method . It is another object of the present invention to provide a method for forming a three-dimensional solid knitted product that can simplify the mold structure and reduce both the manufacturing cost and the manufacturing period of the mold .

In order to solve the above-mentioned problems, in the present invention according to claim 1, a three-dimensional solid knitted product is formed by setting a three-dimensional solid knitted fabric between an upper die and a lower die, heating and cooling, and forming the predetermined shape. In the method, the three-dimensional solid knitted fabric is appropriately engaged with the upper die and the lower die, and the shape forming portion other than the engaged portion is not pressurized by the upper die and the lower die. A three-dimensional three-dimensional knitted product characterized by being set between the upper die and the lower die under heat and heat-treated to deform the shape forming part into a form along the inner surface of the upper die and the lower die. A molding method is provided.
According to a second aspect of the present invention, at least a part of the gap between the upper mold and the lower mold at the time of molding is adjusted to be equal to or greater than the thickness of the three-dimensional solid knitted product, and the molding is performed. A method for forming a three-dimensional solid knitted fabric of
In the third aspect of the present invention, the three-dimensional solid knitted product according to claim 1, wherein the upper die and the lower die are formed by locking the vicinity of the end of the three-dimensional solid knitted fabric. A forming method is provided.
In this invention of Claim 4, what was formed from the punching metal is used as the said upper mold | type and a lower mold | type, The three-dimensional solid knitted product of any one of Claims 1-3 characterized by the above-mentioned. A forming method is provided.
The present invention according to claim 5 is applied to molding of a seat material for a seat for a transport device including an aircraft, an automobile, and a railway vehicle, or a structural material for a seat. A method for forming a three-dimensional three-dimensional knitted product according to claim 1 is provided.

  The present invention is characterized in that a three-dimensional solid knitted fabric is formed by being set between the upper die and the lower die in a non-pressurized state where at least a part thereof is not pressurized by the upper die and the lower die. The three-dimensional solid knitted fabric to be processed is knitted and then heat-set to be provided as a flat plate-shaped original fabric. The heat set corrects and smoothes the unevenness of the surface when knitting, so by performing heat setting, the ground yarn and connecting yarn that make up the ground are pressed in the thickness direction more than when knitting. It has been deformed by heat. In the present invention, the three-dimensional solid knitted fabric thus provided is heated by being set between the upper die and the lower die in a non-pressurized state. And the residual stress of the connecting yarn is released between the upper die and the lower die, so to speak, it deforms along the die so as to be deformed to the state at the time of knitting before heat setting. Therefore, the three-dimensional solid knitted product molded into a predetermined shape has a thickness that is substantially the same as or thicker than the three-dimensional solid knitted fabric before processing, and is not formed by heat compression. The compression restoration performance is almost the same as that of the three-dimensional solid knitted fabric before processing.

  In addition, unlike the conventional heat compression molding, it is not necessary to force the mold shape along with the pressure of the mold, and the residual stress of the three-dimensional solid knitted fabric itself is released by heat as described above. This is to match the shape of the mold. For this reason, as a metal mold | die, it can be set as a simpler structure than the metal mold | die used at the time of pressure compression molding, and it can also manufacture using a punching metal. Therefore, the manufacturing cost and manufacturing period of the mold can be greatly reduced.

  Hereinafter, the present invention will be described in more detail based on the embodiments shown in the drawings. 1 and 2 are diagrams showing the manufacturing process of this embodiment. As shown in these drawings, first, the three-dimensional solid knitted fabric 10 to be processed is cut into a predetermined shape that can be easily set on the mold 20, such as a substantially rectangular shape or a substantially circular shape.

  Here, the three-dimensional three-dimensional knitted fabric 10 is a three-dimensional tertiary knitted fabric having a pair of ground knitted fabrics spaced apart from each other and a large number of connecting yarns that reciprocate between the pair of ground knitted fabrics to couple them together. The knitted fabric has the original structure. One ground knitted fabric is formed by, for example, a flat knitted fabric structure (fine stitches) that is continuous in both the wale direction and the course direction from a yarn obtained by twisting a single fiber. For example, a knitted structure having a honeycomb-shaped (hexagonal) mesh is formed from a yarn obtained by twisting short fibers. Of course, this knitted fabric structure is arbitrary, and it is also possible to adopt a knitted fabric structure other than a fine structure or a honeycomb shape, and a combination thereof is also arbitrary, such as adopting a fine structure for both. The connecting yarn is knitted between the pair of ground knitted fabrics such that one ground knitted fabric and the other ground knitted fabric maintain a predetermined distance, and gives a predetermined rigidity to the three-dimensional solid knitted fabric. . The thickness of the ground yarn forming the ground knitted fabric is selected so that the waist strength necessary for the three-dimensional solid knitted fabric can be provided and the knitting operation does not become difficult.

  Examples of the material of the ground yarn or the connecting yarn include synthetic fibers such as polypropylene, polyester, polyamide, polyacrylonitrile, and rayon, and natural fibers such as recycled fibers, wool, silk, and cotton. These materials are used alone. These may be used in combination. Preferably, thermoplastic polyester resins represented by polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide resins represented by nylon 6, nylon 66, etc., polyolefin resins represented by polyethylene, polypropylene, etc. Or polytrimethylene terephthalate (PTT) or a resin obtained by mixing two or more of these resins. Polyester resins are suitable because of their excellent recyclability. Further, the shape of the ground yarn or the connecting yarn is not limited, and may be a round cross-section yarn or a modified cross-section yarn.

  The connecting yarn may be formed in a loop-like stitch in the ground knitted fabric of the surface layer and the back layer, or may be structured to be hooked on the ground knitted fabric of the surface layer and the back layer by the insertion structure, but at least two connecting yarns However, in order to improve the form stability of the three-dimensional solid knitted fabric, it is preferable that the knitted fabrics of the surface layer and the back layer are inclined obliquely in opposite directions and connected in a cross shape (X shape) or a truss shape.

  The three-dimensional knitted fabric can be knitted with a knitting machine having two rows of needle beds facing each other. Examples of such a knitting machine include a double raschel knitting machine, a double circular knitting machine, and a flat knitting machine having a V bed. In order to obtain a three-dimensional solid knitted fabric with good dimensional stability, it is preferable to use a double raschel knitting machine. The three-dimensional knitted fabric finishes the knitted raw machine through processes such as scouring, dyeing and heat setting. The heat setting is performed, for example, by dry heat at 150 ° C. for 1 minute, and finished into a flat plate having a smooth surface. The three-dimensional solid knitted fabric that has been subjected to the finishing process is wound as a roll and provided as an original fabric, for example. In the present embodiment, the original fabric wound in a roll shape is drawn out for a predetermined length and cut into a predetermined shape as described above.

  The three-dimensional three-dimensional knitted fabric 10 cut into a predetermined shape is set between an upper mold 21 and a lower mold 22 constituting the mold 20 as shown in FIG. When setting, an appropriate portion of the three-dimensional solid knitted fabric 10, for example, the vicinity of the end 11 is locked to the upper mold 21 and the lower mold 22. The means for locking the vicinity of the end 11 to the upper mold 21 and the lower mold 22 is arbitrary. For example, the upper mold 21 and the end locking sections 21a and 22a of the lower mold 22 where the vicinity of the end 11 is located, It can also be locked using a pin member or the like, and as shown in FIG. 2, the interval between the end locking portions 21a and 22a of the upper mold 21 and the lower mold 22 is set to the three-dimensional solid knitted fabric 10 to be processed. By adjusting so as to be narrower than the thickness, the end portion locking portions 21a and 22a can be sandwiched and locked.

  The upper die 21 and the lower die 22 for molding a portion (hereinafter referred to as “shape molding portion”) 12 other than the end portion 11 sandwiched between the end portion locking portions 21a and 22a are the end portion locking portions at the time of molding. The portions excluding 21a and 22a are set at intervals that do not pressurize the shape forming portion 12 of the three-dimensional solid knitted fabric 10. That is, as shown in FIG. 2, the distance between the upper die 21 and the lower die 22 excluding the end locking portions 21a and 22a is substantially the same as or greater than the thickness of the three-dimensional solid knitted fabric 10 to be processed. Also set at wide intervals.

  Next, as shown in FIG. 1B, the three-dimensional solid knitted fabric 10 set in the mold 20 is accommodated in, for example, a heating furnace 30 and heat-treated. Since the three-dimensional solid knitted fabric 10 is set so that the shape forming portion 12 is not pressed by the upper die 21 and the lower die 22 as described above, the ground yarn of the ground knitted fabric constituting the three-dimensional solid knitted fabric 10 is provided. The connecting yarn is deformed until the form is stabilized by the residual stress so that the thermal deformation at the time of heat setting is released. As a result, the shape forming portion 12 of the three-dimensional solid knitted fabric is deformed between the upper die 21 and the lower die 22 in a form along the inner surface of the die even though it is not pressurized.

  On the other hand, the end 11 held between the end locking portions 21a and 22a is adjusted to be narrower than the thickness of the three-dimensional solid knitted fabric 10 before processing in the present embodiment. The deformation of the ground yarn and the connecting yarn of the portion 11 is in the surface direction and is deformed so as to be thinner than the thickness of the three-dimensional solid knitted fabric 10 before processing. Since the end portion 11 is deformed in this manner, the elasticity in the thickness direction is smaller than that of the shape forming portion 12, but the end portion 11 is connected to another member, for example, a frame of a vehicle seat. Since the thickness is reduced, the sewing work for connection is facilitated.

  The upper mold 21 and the lower mold 22 constituting the mold 20 are preferably manufactured using a material having high thermal conductivity. Further, unlike conventional heat compression molding, it is not necessary to conform to the shape of the mold by the pressing force of the mold 20, so that it can be easily manufactured using punching metal.

  In addition, although the temperature at the time of heating in this embodiment changes also with heating time, the thickness of a three-dimensional solid knitted fabric, etc., it is more than the temperature at the time of heat setting, and the ground yarn and connecting yarn which comprise the three-dimensional solid knitted fabric 10 It is preferable to set the heating temperature to 140 to 170 ° C. for a heating time of 3 to 5 minutes or less.

  After the heat treatment, for example, forced cooling is performed until the temperature reaches about 80 ° C. or less (see FIG. 1C), and when the mold is removed (see FIG. 1D), a three-dimensional three-dimensional knitted product 50 having a desired shape is obtained. . Since the obtained three-dimensional three-dimensional knitted product 50 is formed as described above, the thickness of the shape forming portion 12 is not thinner than before processing, and conversely, between the upper die 21 and the lower die 22. Depending on the gap, it becomes thicker than before processing, close to the thickness at the time of knitting before heat setting, and the elasticity and compression recovery in the thickness direction are almost the same or larger than before processing .

  In addition, the use of the three-dimensional solid knitted product obtained by the present invention is arbitrary, and for example, it can be used as a cushion material for seat sheets for transportation equipment including aircraft, automobiles, and railway vehicles. Further, it can also be used as a backboard, a garnish, or a panel material for frame reinforcement, which is a structural material for these seats. Further, when used as a reinforcing panel material or the like, it is preferable to laminate a multiaxial woven fabric such as a four-axis woven fabric, a synthetic leather, or the like by adhesion or the like because strength is improved.

Fig.1 (a)-(d) is a figure for demonstrating the shaping | molding method of the three-dimensional solid knitted product based on one Embodiment of this invention. FIG. 2 is a cross-sectional view showing a state when a three-dimensional solid knitted fabric to be processed is set in a mold.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 3D solid knitted fabric 11 End part 12 Shape molding part 20 Mold 21 Upper mold 22 Lower mold 50 3D solid knitted product

Claims (5)

A method of forming a three-dimensional solid knitted product by setting a three-dimensional solid knitted fabric between an upper mold and a lower mold, heating and cooling, and molding the molded product into a predetermined shape,
The three-dimensional three-dimensional knitted fabric is appropriately locked with the upper mold and the lower mold at the portion, and the shape forming portion which is a portion other than the locked portion is not pressed by the upper mold and the lower mold. A method for forming a three-dimensional solid knitted product, which is set between a mold and a lower mold, is heat-treated, and the shape forming portion is deformed into a shape along the inner surfaces of the upper mold and the lower mold . 2. The method for forming a three-dimensional solid knitted fabric according to claim 1, wherein at least a part of the space between the upper die and the lower die at the time of molding is adjusted to be equal to or greater than the thickness of the three-dimensional solid knitted fabric. The method for forming a three-dimensional solid knitted product according to claim 1, wherein the upper die and the lower die are formed by engaging the vicinity of the end of the three-dimensional solid knitted fabric. The method for forming a three-dimensional three-dimensional knitted product according to any one of claims 1 to 3, wherein the upper die and the lower die are made of punching metal. The three-dimensional three-dimensional knitted fabric according to any one of claims 1 to 3, wherein the three-dimensional knitted fabric is applied to molding a cushion material for a seat for a transport device including an aircraft, an automobile, and a railway vehicle or a structural material for a seat. Molding method of the molded product.

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