JPH06313248A - Production of thick woven or knitted fabric - Google Patents

Abstract

PURPOSE:To produce a lightweight, bulky and thick woven or knitted fabric exhibiting excellent shape stability by weaving or knitting and heat-treating the woven or knitted fabric. CONSTITUTION:Filament yarn of highly shrinkable synthetic fiber having >=20% shrinkage percentage in boiling water and >=0.2g/d maximum thermal stress value is used as yarn constituting its ground fabric at both sides of the surface and the back and the yarn is woven or knitted in >=5mm thickness to produce the objective thick woven or knitted fabric.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention has a multilayer three-dimensional structure,
Lightweight and bulky, as well as general clothing and sports clothing,
The present invention relates to a thick woven or knitted fabric suitable as an industrial material as various functional base fabrics.

[0002]

2. Description of the Related Art In recent years, a number of three-dimensional woven and knitted fabrics have been proposed for general clothing, sports clothing, and base fabrics for various materials. However, when such a three-dimensional woven or knitted fabric is used as clothes or various materials, it is subjected to mechanical external force such as compression, tension, bending, etc., so that its three-dimensional shape becomes asymmetric, or the three-dimensional appearance disappears. It has drawbacks such as

[0003]

Therefore, according to the present invention, it is possible to prevent the shape change due to the external force in the thickness direction, and
It is intended to provide a method for producing a thick woven or knitted fabric capable of maintaining extremely uniform bulkiness.

[0004]

SUMMARY OF THE INVENTION The present invention is to solve this problem by providing a highly shrinkable yarn having a boiling water shrinkage of 20% or more and a maximum thermal stress value of 0.2 g / d or more as a surface-based yarn. A thick woven or knitted fabric, which is used as a yarn to form a cloth and a back base cloth, and is knitted or woven by connecting the front base cloth and the back base cloth with a connecting yarn so that the thickness is 5 mm or more. The main point is the manufacturing method.

The present invention will be described in detail below. In the method for producing a thick woven or knitted fabric of the present invention, a highly shrinkable yarn having a boiling water shrinkage of 20% or more and a maximum thermal stress value of 0.2 g / d or more is used as a yarn constituting the front and back double-sided base fabric. That is a prerequisite.

The boiling water shrinkage of the highly shrinkable yarn used in the present invention is preferably 25% or more, and at the same time, the temperature at which the thermal stress is maximum is at least 50 ° C. and the maximum thermal stress value is 0. It is preferably 25 g / d or more. The present invention cannot be achieved unless the boiling water shrinkage rate and the maximum thermal stress value are both satisfied at the same time. For example, the boiling water shrinkage is 20%
Even if the maximum thermal stress value is less than 0.2 g / d, sufficient shrinkage behavior cannot be obtained by the heat treatment in the subsequent process, and the maximum thermal stress value is 0.2 g / d or more. However, if the boiling water shrinkage is less than 20%, sufficient shrinkage behavior cannot be obtained as in the former case. In other words, in order to sufficiently shrink the texture points and the stitch structure of the woven or knitted fabric and to improve the compression resistance of the woven or knitted fabric to a high degree, the conventional technique using the boiling water shrinkage ratio as a guide is insufficient. The balance between the shrinkage rate and the thermal stress value in a specific range is important. That is, when either the boiling water shrinkage rate or the thermal stress is lower than the numerical value of the present invention, sufficient shrinkage behavior cannot be obtained.

When the yarn having such a specific shrinkage property is used for the entire surface of the base fabric on the front and back surfaces of the woven or knitted fabric, the object of the present invention can be sufficiently achieved. Alternatively, the above highly shrinkable yarn may be used for all warp yarns. On the other hand, in the case of a knitted fabric, in forming loops on the front and back base fabric surfaces, even if a loop is formed with a highly shrinkable yarn for each course in the course direction or wale direction or for each wale
Since the binding between the loops becomes strong, the object of the present invention can be achieved.

The yarn form having a high shrinkage property in the method of the present invention may be any of monofilament, multifilament, crimped yarn, fluid entangled yarn, spun yarn, various composite yarns and the like.

The second essential condition of the present invention is that the front surface backing cloth and the back surface backing cloth are connected by connecting threads so as to have a thickness of 5 mm or more, and knitting or weaving. If the thickness is less than 5mm,
Since the intermediate layer between the front and back base fabrics is small, it does not become a lightweight and bulky woven or knitted fabric, and does not exceed the range of conventional thick woven and knitted fabrics. The front and back base fabrics are basically composed of warp and weft in the case of woven fabric, warp in warp knitting, and weft in weft knitting. The structure of both the front and back base fabrics is arbitrary, and any structure may be selected depending on the purpose and use. As a means for weaving and knitting, a commercially available double velvet weaving machine, a double Russell knitting machine, or the like may be used.

The present invention will be described below with reference to the drawings.
FIG. 1 is a weaving action diagram showing an embodiment of a method for manufacturing a thick fabric according to the present invention. That is, the front yarn beam (1
The front warp (5) pulled out from 4) is a heddle (not shown)
The surface base cloth (2) is woven by inserting the surface weft (6) into the opening. Similarly, the back warp (7) and the back weft (8) pulled out from the back yarn beam (15) weave the back substrate (3). further,
Connecting thread (4) pulled out from the connecting thread beam (16)
Passes through the middle of the front warp (5) and the back warp (7),
By a special shedding motion of a connecting yarn heddle (not shown), the weft is alternately woven with the front weft (6) and the back weft (8). As a result, the front surface fabric (2) and the back surface fabric (3) are connected to each other by the connecting yarn (4).
Will be linked by. Here, if the yarn having the high shrinkage property described above is used for all of the warp yarns (5) (7) and the weft yarns (6) (8) on the front and back, or for either the warp yarn or the weft yarn, The object of the invention can be achieved.

Next, FIG. 2 is a knitting operation diagram of a method for manufacturing a thick knitted fabric according to another example of the present invention. That is, in the first yarn feeder (F1) of the double circular knitting machine, the back face base fabric is knitted by the dial long needle (DL) and the dial short needle (DS), and at the second yarn feeder (F2), the cylinder long needle (CL). ) And a cylinder short needle (CS), the surface base fabric is knitted. The back surface fabric and the front surface fabric do not have direct contact with each other and are in a separated state. Then, the third
At the yarn feeder (F3), tuck knitting is performed with the dial long needle (DL) and the cylinder long needle (CL), and the front and back base fabrics are connected to each other for the first time. Next, the fourth yarn feeder (F4) and the fifth
The yarn feeder (F5) has a first yarn feeder (F1) and a second yarn feeder (F5), respectively.
The knitting action is the same as that of the yarn feeder (F2), and at the sixth yarn feeder (F6), the dial short needle (DS) and the cylinder short needle (CS) which are knitting needles different from the knitting needles knitted at the third yarn feeder (F3) are used. ) Will be knitted and connected.
Here, all of the first yarn feeder (F1), the second yarn feeder, the fourth yarn feeder and the fifth yarn feeder, or the first yarn feeder (or the fourth yarn feeder) and the second yarn feeder (or the fifth yarn feeder) The method of the present invention can be achieved by feeding the high shrinkage yarn only to the yarn feeding port).

Next, an embodiment of the thick woven or knitted fabric obtained by the method of the present invention will be described with reference to the drawings. FIG. 3 is a schematic longitudinal sectional view of a thick fabric according to an example of the present invention, and FIG. 4 is a schematic cross sectional view of a thick knitted fabric according to an example of the present invention.

The thick fabric (1) of FIG. 3 has a thickness of 5 mm or more, and has a structure in which the front base fabric (2) and the back base fabric (3) are connected by connecting yarns (4). There is. Surface base cloth (2)
The front warp (5) and the surface weft (6) form a flat design, and the back surface backing fabric (3) forms the flat design by the back warp (7) and the back weft (8). In the front and back base fabrics formed in such a separated state, the connecting yarn (4) is the front weft (6).
And a part of the back weft (8) is textured, whereby the two base fabrics are firmly connected.

On the other hand, FIG. 4 shows a schematic cross-sectional view of a thick knitted fabric according to another example of the present invention. That is, the front surface backing cloth (9) and the back surface backing cloth (10) are
1) and the back loop (12) are formed separately, and the front and back base fabrics (9) and (10) are connected by a connecting thread (13). The connecting thread (13) is a double-sided base cloth (9) (10).
On the other hand, they may be connected by a knit loop or a tuck loop.

Since the thick woven or knitted fabric of the present invention has the above-mentioned structure, if the highly shrinkable yarns are evenly arranged on both the front and back base fabrics, the morphological stability is improved. It can be improved. That is, when the high shrinkage yarns cause a heat shrinkage action in the part where both the base fabrics on the front and back sides and the connecting yarns are joined, the texture points of the woven fabric or the stitch connecting portions of the knitted fabric are tightly held in a well-balanced manner. The binding part will be immobilized extremely robustly. As a result, the warp of woven and knitted fabrics,
Almost no plastic deformation occurs even if external force is applied in each direction of weft and thickness.

[0016]

[Working] As in the present invention, the yarn constituting the front and back double-sided base fabric has a boiling water shrinkage ratio of 20% or more and a maximum thermal stress value of 0.2.
If a yarn having a high shrinkage property of g / d or more is used, even if the thickness is 5 mm or more, the intersection of the warp and the weft and the stitch connection point are firmly tightened by the heat treatment after weaving and knitting, so that the intersection It is unlikely that there will be a shift at the knitting point and the stitch connecting point, and at the same time the binding force with the connecting yarn that connects the front and back base fabrics will be improved, and the three-dimensional shape can be maintained without plastic deformation due to external force.

[0017]

EXAMPLES Examples of the present invention will be described below. Example 1 Using a velvet loom, the boiling water shrinkage ratio of all the warp yarns and weft yarns of the front and back double-sided base fabric was 22.5% in the design shown in FIG.
And a polyester filament of 340 denier 48 filament with a maximum thermal stress value of 0.22 g / denier,
A polyester filament of 340 denier 48 filament having a boiling water shrinkage of 8.3% and a maximum thermal stress value of 0.13 g / denier was used as the connecting yarn, and the thickness was 7.5.
mm fabric was woven.

Example 2 In Example 1, the weft yarns on both the front and back sides were replaced with polyester filaments of 340 denier 48 filament having a boiling water shrinkage of 22.5% and a maximum thermal stress value of 0.22 g / denier. A polyester filament of 340 denier 48 filament having a boiling water shrinkage of 9.2% and a maximum thermal stress value of 0.15 g / denier was prepared in the same manner as in Example 1 and had a thickness of 6.9 mm. The fabric was woven.

Example 3 In Example 1, the warp of the front and back double-sided base fabric was replaced with a polyester filament of 340 denier 48 filament having a boiling water shrinkage of 22.5% and a maximum thermal stress value of 0.22 g / denier. In the same manner as in Example 1, except that a boiling water shrinkage rate of 9.2% and a maximum thermal stress value of 0.15 g / denier of 340 denier 48 filament polyester filament were used, and the thickness was 6.2 mm. The fabric was woven.

Comparative Example 1 In Example 1, all of the warp yarns and weft yarns of the front and back double-sided base fabric had a boiling water shrinkage of 22.5% and a maximum thermal stress value of 0.2.
2 g / denier 340 denier 48 filament polyester filament replaces boiling water shrinkage of 1
8.5%, the maximum thermal stress value is 0.21 g / denier of 3
A woven fabric having a thickness of 7.5 mm was woven in the same manner as in Example 1 except that a polyester filament of 40 denier and 48 filament was used.

Comparative Example 2 In Example 1, all of the warp yarns and weft yarns of the front and back double-sided base fabric had a boiling water shrinkage of 22.5% and a maximum thermal stress value of 0.2.
2 g / denier 340 denier 48 filament polyester filament replaces boiling water shrinkage of 2
3.3% and maximum thermal stress value of 0.18 g / denier 3
A woven fabric having a thickness of 7.5 mm was woven in the same manner as in Example 1 except that a polyester filament of 40 denier and 48 filament was used.

Comparative Example 3 In Example 1, all the warp yarns and weft yarns of the front and back double-sided base fabric had a boiling water shrinkage of 22.5% and a maximum thermal stress value of 0.2.
Polyester filament of 340 denier 48 filament of 2 g / denier was replaced with polyester filament of boiling water shrinkage of 23.3%, maximum thermal stress value of 0.18 g / denier of 340 denier 48 filament, weft was boiling. A fabric having a thickness of 6.9 mm was prepared in the same manner as in Example 1 except that the polyester filament was a 340 denier 48 filament having a water shrinkage of 9.2% and a maximum thermal stress value of 0.15 g / denier. Woven

Embodiment 4 A dial / cylinder type circular knitting machine is used to fabricate a knitting action diagram shown in FIG. 2 into a first yarn feeder (F1) and a second yarn feeder (F).
2), the boiling water shrinkage rate is 22.3% and the maximum thermal stress value is 0.22g at the fourth yarn feeder (F4) and the fifth yarn feeder (F5).
/ Denier 150 denier 48 filament polyester filament is fed to form the front and back base fabrics, and the boiling water shrinkage rate is 9.2% at the third yarn feeder (F3) and the sixth yarn feeder (F6). A polyester filament of 150 denier 30 filament having a maximum thermal stress value of 0.14 g / denier is fed and the base fabrics on the front and back sides are connected to each other to have a thickness of 6.5.
mm knitting was made.

Example 5 In Example 4, the boiling water shrinkage rate of the first yarn feeder (F1) and the second yarn feeder (F2) was 22.3%, and the maximum thermal stress value was 0.22 g / denier of 150. Instead of feeding polyester filament of 48 denier filament, boiling water shrinkage is 22.3% and maximum thermal stress value is 0.
A knit fabric having a thickness of 6.5 mm was knitted in the same manner as in Example 4 except that 22 g / denier of 150 denier 48 filament polyester filament was supplied. In this knitted fabric, highly shrinkable yarns are knitted for each course of the front and back base fabrics.

Example 6 Using a dial / cylinder type circular knitting machine, the boiling water shrinkage rate of 8.8 was obtained in the first yarn feeder (F1) and the second yarn feeder (F2) with the structure shown in the knitting action diagram in FIG. %, The maximum thermal stress value was 0.12 g / denier and the polyester filament of 150 denier 48 filament was fed, and the third yarn feeder (F3), the fourth yarn feeder (F4), the fifth yarn feeder (F5) and The contraction rate of boiling water at the sixth yarn feeder (F6) is 22.3%,
A polyester filament of 150 denier 48 filament with a maximum thermal stress value of 0.22 g / denier is fed, and a highly shrinkable yarn is knitted for each course of the front and back base fabrics, and all of the connecting yarns have high shrinkability. Yarn, thickness 6.5
mm knitting was made.

Comparative Example 4 In Example 4, the first yarn feeder (F1), the second yarn feeder (F2), the fourth yarn feeder (F4) and the fifth yarn feeder (F5).
The boiling water shrinkage is 22.3% and the maximum thermal stress value is 0.2.
Instead of feeding polyester filament of 150 denier 48 filament of 2 g / denier, boiling water shrinkage is 23.5% and maximum thermal stress value is 0.18 g /
A knit fabric having a thickness of 6.5 mm was knitted in the same manner as in Example 4 except that polyester filament of 150 denier 48 filament of denier was supplied.

Comparative Example 5 In Example 4, the first yarn feeder (F1), the second yarn feeder (F2), the fourth yarn feeder (F4) and the fifth yarn feeder (F5).
The boiling water shrinkage is 22.3% and the maximum thermal stress value is 0.2.
Instead of feeding polyester filament of 150 denier 48 filament of 2 g / denier, boiling water shrinkage rate is 18.8% and maximum thermal stress value is 0.25 g /
A knit fabric having a thickness of 6.5 mm was knitted in the same manner as in Example 4 except that polyester filament of 150 denier 48 filament of denier was supplied.

Comparative Example 6 In Example 4, the first yarn feeder (F1), the second yarn feeder (F2), the fourth yarn feeder (F4) and the fifth yarn feeder (F5).
The boiling water shrinkage is 22.3% and the maximum thermal stress value is 0.2.
Instead of feeding 150 g denier 48 filament polyester filament at 2 g / denier,
A polyester filament of 150 denier 48 filament having a boiling water shrinkage of 8.8% and a maximum thermal stress value of 0.12 g / denier was added to the yarn feeder (F1) and the second yarn feeder (F2), and the fourth yarn feeder ( F4) and fifth yarn feeder (F5)
The boiling water shrinkage is 18.8%, and the maximum thermal stress value is 0.2.
Example 4 except that 5 g / denier of 150 denier 48 filament polyester filament was fed.
Similarly to the above, a knitted fabric having a thickness of 6.5 mm was knitted. Table 1 shows the results of evaluating the compression resistance of the obtained 12 points of Examples 1 to 6 and Comparative Examples 1 to 6 by dyeing and finishing by a conventional method.

The evaluation method of the compression resistance is as follows. A sample is cut into a size of 5 cm x 5 cm, a load is applied in the thickness direction of the sample using a self-recording compression tester manufactured by Shimadzu Corporation, and the stress value up to 50% compression is measured. The stress, the maximum stress value up to 50% compression, and the compressibility at the maximum stress were evaluated. Furthermore, the weight was removed at the same time as 50% compression, and the recovery rate after standing for 1 minute was measured.

[0030]

[Table 1]

As is clear from Table 1, the six points of the examples have a large stress at 50% compression, a maximum stress value up to 50% compression and a high recovery rate, and have excellent compression resistance. However, in all 6 points of the comparative example, the resistance to compression was weak.

[0032]

EFFECTS OF THE INVENTION A feature of the method for producing a thick woven or knitted fabric according to the present invention is that a highly shrinkable synthetic fiber filament yarn exhibiting a specific boiling water shrinkage ratio and a maximum thermal stress value is used as a yarn constituting both front and back base fabrics. It is used and weaving and weaving while keeping the thickness between the front and back base fabrics to be 5 mm or more. The woven and knitted fabric thus obtained has a lightweight and bulky structure because when it is heat-treated in a higher-order process, the above-mentioned highly shrinkable yarn acts tightly to tightly bind the woven structure points and the stitch bonding points. However, the morphological stability against compression and tension becomes remarkably firm, and it can be applied to clothing and materials with good cushioning and cushioning properties. Further, even when it is impregnated with a matrix resin or the like and used as a base material of a composite material, a more uniform form can be obtained by heating during resin molding.

[Brief description of drawings]

FIG. 1 is a weaving action diagram of a thick fabric according to an example of the present invention.

FIG. 2 is a knitting operation diagram of a thick knitted fabric according to an example of the present invention.

FIG. 3 is a schematic longitudinal sectional view of a thick fabric according to an example of the present invention.

FIG. 4 is a schematic cross-sectional view of a thick knitted fabric according to an example of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Thick fabric 2 Surface base fabric 3 Back face fabric 4 Connecting yarn 5 Front warp 6 Front weft 7 Back warp 8 Back weft 9 Front base fabric 10 Back base fabric 11 Surface loop 12 Back loop 13 Connecting yarn 14 Front yarn beam 15 Back yarn Beam 16 Connected thread beam DL Dial long hand DS Dial short hand CL Cylinder long hand CS Cylinder short hand

Claims (1)

[Claims] 1. A highly shrinkable yarn having a boiling water shrinkage of 20% or more and a maximum thermal stress value of 0.2 g / d or more is used as a yarn constituting a surface backing and a backing backing, and has a thickness. A method for producing a thick woven or knitted fabric, which comprises knitting and knitting by connecting the front surface backing cloth and the back surface backing cloth with connecting threads so that the length becomes 5 mm or more.