JPH04222260A - Three-dimensional structure web - Google Patents

Abstract

PURPOSE:To provide a three-dimensional structure web having an uneven surface, specific space index, specified thickness, excellent cushioning property, and excellent air permeability by binding face and back fabric tissues with plural kinds of filaments having a specific difference between their shrinkage degrees and subsequently subjecting the fabric tissues to a thermal treatment. CONSTITUTION:Face and back fabric tissues are subjected to a knitting or weaving treatment with a double raschel knitting machine or moquette loom using two kinds of monofilaments or multifilaments (the number of the filaments is relatively a few) having a difference of >=5% between their shrinkage degrees. The knit or woven fabric is heated to provide a three-dimensional structure web having an uneven surface, a thickness of 1-15mm and a space index K of 0.4-0.98 satisfied with an equation: K=1-(W/C.T) wherein W (g/m<2>) is the weight of the web; C(g/cm<3>) is the average density of the fiber raw material; and T(cm<3>/m<2>) is the volume of the web.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The three-dimensional structured fabric of the present invention has an appropriate amount of voids on the inside and outside of the three-dimensional structured fabric, has excellent breathability, and has excellent cushioning properties. Skin materials or fillings for mattresses, cushions, sheets, seat covers, bedding pads, medical pads, etc., skin materials for clothing such as blouson, down, jumpers, etc., or skin materials or spacers for bags, bags, etc., car mats, The present invention relates to a three-dimensional structured fabric used for mats such as floor mats, helmets, liners for hats, etc., daily miscellaneous goods such as health towels, cleaners, etc.

0002

[Prior Art] Conventionally, skin materials and filling materials used in the above-mentioned fields of application include flat or napped fabrics, knitted fabrics, and thick non-woven fabrics for cleaners for daily miscellaneous goods. ing. On the other hand, in the case of stuffing, polyester fibers, polyamide fibers, cotton, wool, or elastic foams such as urethane foam were used, as typified by bed pine tresses, pads, and mattresses.

However, these skin materials and filling materials have poor air permeability, water transpiration, compressive elasticity, water drainage, etc.
Depending on the application, it may have a fatal drawback or be inferior in terms of comfort and hygiene. In particular, bed mats, pads,
When sleeping or sitting on a rug such as a futon, the close contact with the body may cause discomfort during hot and humid times such as summer, and in the case of bedridden elderly people, they may lie down 24/7 regardless of the season. As a result, water vapor such as sweat emitted from the body is extremely slow to evaporate to the outside, which can lead to bedsores.

0004

[Problems to be Solved by the Invention] In order to solve these conventional problems, the present invention has a three-dimensional structural fabric with an appropriate amount of voids on the inside and outside, and has excellent breathability and cushioning properties.
The present invention aims to provide a three-dimensional structural fabric with improved design.

[0005]

[Means for Solving the Problems] The present invention provides a three-dimensional structured fabric in which the front and back fabrics are connected by connecting yarns, in which two or more types of yarns having shrinkage rates different by 5% or more are used as the connecting yarns. , the void index K shown by the following formula is 0.4 to 0.98,
Three-dimensional structured fabric having a thickness of 1 to 15 mm (Claim 1)
The present invention also provides a three-dimensional structured fabric (claim 2) in which the three-dimensional structured fabric is heat-treated after weaving and weaving to develop irregularities in its external shape.

The present invention will be explained in detail below with reference to the drawings. 1 and 2 are schematic cross-sectional views of a three-dimensional structured fabric according to the present invention. FIG. 1 is a schematic cross-sectional view of a three-dimensional structured fabric before being subjected to heat treatment, and FIG. 2 is a schematic cross-sectional view of a three-dimensional structured fabric whose external shape has been made uneven by heat treatment. FIG. 3 is a schematic perspective view of a three-dimensional structured fabric whose external shape has been made uneven by heat treatment.

The three-dimensional structured fabric of the present invention is knitted and woven using a double lattice knitting machine, a moquette loom, or the like. More specifically, the front fabric 1 and the back fabric 2 shown in FIGS. 1 to 3 are connected by connecting threads 3 to form a three-dimensional fabric. The fiber material used for the front and back textures may be any of synthetic fibers, regenerated fibers, natural fibers, inorganic fibers, etc., and may be yarns spun alone or in a mixture. Furthermore, these yarns may be of the same type on the front and back, different types, or mixed or interwoven, without any limitation.

[0008] Any texture can be adopted as the ground texture on the front and back sides, and the characteristic combinations of textures are: - Both the ground textures 1 and 2 on the front and back are mesh-like, and - The ground texture 1 on the front side is mesh-like and the texture on the back side is mesh-like. Ground texture 2 is flat, and ground texture 1 and 2 on the front and back are both flat. Of course, there is no limitation in the case where mesh-like and flat textures coexist on one or both of the front and back sides.

[0009] The front fabric structure 1 and the back fabric fabric 2 are connected by connecting threads 3.
It is three-dimensionally continuous. As the material used for the connecting thread 3, synthetic fibers such as nylon 6, nylon 66, polyester, polyethylene, and polypropylene fibers are preferred. In the present invention, the connecting yarn 3 uses a connecting yarn with a small shrinkage rate and a connecting yarn with a high shrinkage rate, and the difference in shrinkage rate is 5%.
The above is considered the most important component. Here, the shrinkage rate is measured under the conditions of JIS L 1013 7.15 hot water shrinkage rate (100° C. 30 min). The connecting yarn with a low shrinkage rate and the connecting yarn with a high shrinkage rate may be made of the same type of fibers manufactured under different manufacturing conditions, or may be made of different types of fibers with different shrinkage rates.

[0010] This difference in shrinkage rate is essential for producing unevenness in the external shape of the three-dimensional structured fabric by heat-treating the knitted and woven fabric. The disposed portion 4 becomes the convex portion 7 (inner void) shown in FIG. 2 after heat treatment, and the portion 4 shown in FIG. 1 where the connecting yarn with a large shrinkage rate is disposed becomes the concave portion 6 (outer void) shown in FIG. 2 after heat treatment. Further, it is preferable from the viewpoint of appearance and function that the difference in shrinkage rate is 7 to 80%. If the difference in shrinkage rate is less than 5%, the difference between the convex portions 7 and the concave portions 6 is difficult to appear in the external shape of the three-dimensional structure fabric, and the voids on the outside may be insufficient or the value may not be recognized. It becomes something that does not exist. Furthermore, connecting yarns with a low shrinkage rate require an appropriate amount of voids and compressive elasticity.
Monofilament yarns having a diameter of 0.05 to 0.4 mm or multifilament yarns having a relatively small number of filaments are suitable. The connecting yarn with a higher shrinkage rate, whether monofilament or multifilament, should have a shrinkage rate 5% or more greater than the connecting yarn with a lower shrinkage rate, and the difference in shrinkage rate depends on the required texture and performance. , any selection suitable for the appearance etc. may be made. In addition, there is no problem when combining three or more types of connecting threads with shrinkage rates that differ by 5% or more from each other, and it is possible to change the degree of unevenness, increasing functionality and design value, and creating even more excellent three-dimensional It becomes a structural fabric. The ratio of connecting yarns with a small shrinkage rate to connecting yarns with a high shrinkage rate is in the range of 2 to 70% of the total connective yarns, but if it is 5 to 60%, it will not work in terms of functionality. , resulting in a three-dimensional structured fabric that is desirable from a design standpoint.

[0011] The spacing, arrangement, arrangement direction, etc. of the connecting threads 3 are matters that can be arbitrarily determined as necessary. For example, the front and back textures may be connected in the vertical direction, arranged in a sash, diagonally, or in a combination of any two of the vertical, slit, and diagonal directions. You may also connect them. Of course, the connecting threads 3 may be arranged in a partially toothless arrangement. Furthermore, in the case of Fig. 3, the arrangement direction is such that the recesses 6 appear linearly after heat treatment, but it is also effective to arrange them in a jagged structure, or in a diamond shape, a honeycomb shape, or in any other way. It is.

The void index K required to provide functions such as air permeability, compressive elasticity, heat dissipation, heat retention through air inclusion, and water permeability is from 0.4 to 0.98, but more preferably from 0.4 to 0.98. 6～
It is 0.97. The void index K indicates the amount of voids in the three-dimensional fabric by subtracting the volume of the threads constituting the three-dimensional fabric from the apparent volume per unit area. In addition, the average density C of the fiber material is the density when all the fiber materials making up the three-dimensional structure fabric are of the same type, and the weight of the density of each fiber material when there are multiple types of fiber materials. Average. If the porosity index K is less than 0.4, the amount of pores is small, resulting in poor air permeability, water evaporation properties, and cushioning properties, which is not preferable. On the other hand, if it exceeds 0.98, the amount of voids becomes too large, making it difficult to maintain the three-dimensional shape, and the compression resistance becomes too low, which is not preferable.

The thickness of the three-dimensional structured fabric of the present invention is 1 to 1
It is 5mm. Preferably, 2 to 13 mm is suitable from the viewpoint of function and commercial value. If it is less than 1 mm, the meaning of three-dimensionality will be diminished, and at the same time, the unevenness will be poor, and the fabric will have little value as a three-dimensional structured fabric. Moreover, if it exceeds 15 mm, the compression resistance becomes small and it becomes difficult to maintain the three-dimensional shape during use. The thickness in this case means the thickness before heat treatment, and does not apply to the thickness after heat treatment. Although the three-dimensional structured fabric shown in FIG. 1 obtained above can be used as it is as an excellent three-dimensional structured fabric in the above-mentioned industrial application fields, heat treatment is applied to the three-dimensional structured fabric shown in FIG. By utilizing the shrinkage rate difference between the connecting yarn with a small heat shrinkage rate and the connecting yarn with a high heat shrinkage rate, the convex part 7 and the concave part 6 as shown in Fig. 2 are developed, and the concave part 6 is formed on the outside of the three-dimensional structure material.
By creating these voids, superior air permeability, moldability, and visual commercial value can be obtained.

[0014] The heat treatment may be performed in a wet state using steam, hot water, etc., or dry heat using a tenter or the like, or a combination of both methods, and a method that can maintain the three-dimensional structure may be selected. For example, it is preferable to perform hot water treatment while passing it through a hot water bath in the form of a spread cloth. After that, in order to stabilize the fabric shape, a pin tenter was used to stabilize the fabric shape.
One example is a heat setting finish set at a temperature of 70°C for 1 to 3 minutes. As described above, it has an uneven appearance,
Three-dimensional structured fabrics can be provided that are suitable for a wide variety of applications.

[0015]

[Function] The three-dimensional structured fabric of the present invention connects the front and back fabrics with connecting yarns having appropriate rigidity, thereby ensuring a large gap between the front fabric and the back fabric. Moreover, since these voids have excellent compressive elasticity due to the rigidity of the connecting threads, they have functions such as air permeability, water permeability, and water evaporation properties. Furthermore, since the connecting yarns are mixed with yarns with shrinkage percentages that differ by 5% or more, heat treatment after knitting and weaving causes the appearance of the front and back surfaces of the three-dimensional structured fabric to become uneven. This will also create voids on the outside. This means that the compression resistance increases during pressurization, and
It also serves to make the void more robust.

[0016]

Embodiments Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Example 1 First, a three-dimensional structured fabric shown in FIG. 1 before heat treatment was created by the following method. The surface texture 1 is polyester 250
A small mesh-like structure is knitted with two reeds using d/48f multifilament, and polyester 250d/48f multifilament is arranged on the back side fabric 2, similar to the front side fabric, and the two reeds provide dimensional stability. The ground structure was flat with good texture. As the connecting yarn 3, 14 220D monofilaments made of nylon 6 with a boiling water shrinkage rate of 8% are arranged in succession as a connecting yarn with a small shrinkage rate, and adjacent to these, nylon 6 is used as a connecting yarn with a high shrinkage rate. Boiling water shrinkage rate 35
% 220d monofilament were arranged in succession, and thereafter these two kinds were arranged repeatedly, and they were organized with two reeds so that a straight recess 6 could be generated after heat treatment. The knitting machine is
A 14 gauge double ratchet machine (manufactured by Karl Mayer) was used. The resulting three-dimensional structured fabric has a thickness of 6.5 m.
m, void index K was 0.91, and area weight was 620 g/m2.

[0017] The three-dimensional structured fabric thus obtained was rolled up in an expanded form into a dyeing machine equipped with a drum-shaped reel, heat-treated with boiling water for 30 minutes to sufficiently shrink the connecting threads, and then air-dried. Then, finishing setting was performed at 150° C. for 1 minute using a pin tenter (manufactured by Ichikin Kogyo Co., Ltd.) to develop convex portions 7 and concave portions 6 as shown in FIG. When this three-dimensional structured fabric was used as the skin material for bed pads in combination with hard cotton, a void was created between the human body and the pad, allowing air to exchange through breathability, resulting in a lasting cool feeling even when sleeping for a long time. ，It was comfortable. Based on this, when used in bedridden elderly patients, the occurrence of bedsores was significantly improved.

Example 2 The three-dimensional structured fabric obtained in Example 1 was installed as a car seat cover in an area that almost covered the backrest and seat. If you drive a car equipped with this car seat for long periods of time in the summer,
Although I drove it during the day, I did not sweat as much as before, the stickiness was significantly improved, and the comfort was significantly improved.

Example 3 A cleaner was prepared by adhering the three-dimensional structured fabric obtained in Example 1 onto a sponge, and was used for washing dishes. It lathered in an appropriate amount, felt good in the hand, and had excellent dishwashing power. Furthermore, it drained water very well and had good air permeability, so it had good drying properties.

Example 4 The three-dimensional structured fabric obtained in Example 1 was lined with vinyl chloride resin to a thickness of 4 mm and used as a floor mat. On rainy days, the rainwater that adheres to the shoes can be easily drained.
It was a comfortable floor mat with almost no redeposition, moderate cushioning properties, and excellent drying properties.

Example 5 The three-dimensional structure fabric of Example 1 was constructed in the same manner as in Example 1, except that polyester 150d/30f and boiling water shrinkage rate of 39% were used for the connecting yarn with a large shrinkage rate. A structural fabric was created. The obtained three-dimensional structured fabric before heat treatment had a thickness of 6.5 mm, a void index K of 0.90, and a fabric weight of 5.
It was 97g/m2. Using this three-dimensional structured fabric, a pad was made in the same manner as the bed pad of Example 1, and when it was put into practical use, the evaluation was exactly the same as in the same example, and it was an excellent three-dimensional structured fabric. .

[0022]

Effects of the Invention The three-dimensional structured fabric according to claim 1 of the present invention has an appropriate thickness and voids, and therefore has excellent cushioning properties and air permeability. This three-dimensional structured fabric uses a mixture of threads with a shrinkage rate difference of 5% or more in the connecting yarn, and the three-dimensional structured fabric of claim 2 which is heat-treated has an uneven external shape. The fabric has a three-dimensional structure with voids on the inside and outside, is thick, has properties such as compression resistance, cushioning properties, breathability, water permeability, and moisture evaporation properties, resulting in breathability, comfort, and Bedding that requires cushioning, etc.
It can be expected to be used in a wide range of other fields, including the medical field, the field of daily necessities and mats that require drainage and drying properties, the clothing field that requires fashion elements, and the field of bags and bags that require thickness and breathability.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view of a three-dimensional structured fabric of the present invention before being subjected to heat treatment.

FIG. 2 is a schematic cross-sectional view of a three-dimensional structured fabric after heat treatment of the present invention.

FIG. 3 is a schematic perspective view of a three-dimensional structured fabric after heat treatment of the present invention.

[Explanation of symbols in the diagram]

1 Front fabric structure 2 Back fabric fabric 3 Connecting yarn 4 Portion with connecting yarn with low shrinkage rate 5 Portion with connecting yarn with high shrinkage rate 6 Recessed portion (outer void) 7 Convex portion (inner void)

Claims (2)

[Claims] Claim 1: A three-dimensional structured fabric in which the front and back fabrics are connected by connecting yarns, in which two or more types of yarns with shrinkage rates different by 5% or more are used, and the voids shown by the following formula are used. A three-dimensional structured fabric having an index K of 0.4 to 0.98 and a thickness of 1 to 15 mm. 2. A three-dimensional structured fabric having an uneven appearance obtained by heat-treating the three-dimensional structured fabric according to claim 1 to develop an uneven appearance.