WO2024106026A1

WO2024106026A1 - Material

Info

Publication number: WO2024106026A1
Application number: PCT/JP2023/035417
Authority: WO
Inventors: 一考酒井; 彰一向井
Original assignee: 東レ株式会社
Priority date: 2022-11-15
Filing date: 2023-09-28
Publication date: 2024-05-23

Abstract

Provided is a material that is easy to produce, lightweight, and has excellent anti-slip properties in areas to which the material is applied. The material has a first surface and a second surface on the side opposite from the first surface, and the material is composed of warp knitted fabric in which multiple polyurethane yarns are arranged on the same course. The basis weight of the material is 100 g/m2 or less, and the proportion (R1) of polyurethane threads exposed on the first surface is greater than the proportion (R2) of polyurethane threads exposed on the second surface.

Description

Materials

The present invention relates to a material. More specifically, the present invention relates to a material that is easy to produce, lightweight, and has excellent anti-slip properties when applied.

　In the past, materials with excellent anti-slip properties for application areas have been developed for bedding such as mattress pads, daily necessities such as bath mats, and also in the fields of clothing such as health clothing and sports clothing, and the medical field (for example, Patent Document 1). Patent Document 1 discloses an elastic warp knitted fabric that is easy to wear on the body, can fix joints, and has the elasticity to follow the movement of the skin in the clothing field, etc.

JP 2013-119671 A

However, the elastic warp knitted fabric described in Patent Document 1 is a warp knitted fabric made using three reeds, and has a large basis weight and is heavy. Furthermore, if the basis weight of the elastic warp knitted fabric described in Patent Document 1 is reduced by reducing the number of reeds, the static friction coefficient decreases and the fabric becomes more slippery at the application location. In order to reduce the weight of the warp knitted fabric, it is possible to use a lighter yarn (such as polyurethane yarn) instead of polyester yarn, for example. However, fabric made of polyurethane yarn has high viscosity and poor processability, making it difficult to produce depending on the mixing ratio of polyurethane yarn.

The present invention was made in consideration of these conventional inventions, and aims to provide a material that is easy to produce, lightweight, and has excellent anti-slip properties in the areas where it is applied.

After extensive research, the inventors discovered that the above problem could be solved by configuring a warp knitted fabric containing polyurethane yarn so that multiple polyurethane yarns are arranged on the same course, and the proportion of polyurethane yarn exposed on the first surface that contacts the application area is greater than the proportion of polyurethane yarn on the second surface opposite the first surface, and thus completed the present invention.

The material of the present invention, which solves the above-mentioned problems, is a material having a first side and a second side opposite to the first side, made of a warp knitted fabric in which multiple polyurethane yarns are arranged on the same course, has a basis weight of 100 g/ ^m2 or less, and the proportion (R1) of the polyurethane yarns exposed on the first side is greater than the proportion (R2) of the polyurethane yarns exposed on the second side.

FIG. 1 is a plan view of a material according to one embodiment of the present invention taken from the first surface side. FIG. 2 is a plan view of a material according to one embodiment of the present invention taken from the second surface side. FIG. 3 is a schematic external view illustrating a polyester yarn and a polyurethane yarn, in which the polyurethane yarn is arranged so as to overlap on the same course.

<Materials>
A material according to one embodiment of the present invention has a first side and a second side opposite to the first side. The material is made of a warp knitted fabric in which a plurality of polyurethane yarns are arranged on the same course. The material has a basis weight of 100 g/ ^m2 or less. The proportion (R1) of the polyurethane yarns exposed on the first side is greater than the proportion (R2) of the polyurethane yarns exposed on the second side. Each of these will be described below.

FIG. 1 is a planar photograph of the material of this embodiment taken from the first surface side. FIG. 2 is a planar photograph of the material of this embodiment taken from the second surface side. In FIG. 1 and FIG. 2, the polyurethane threads are colored black for clarity. FIG. 3 is a schematic external view for explaining how multiple polyurethane threads are arranged on the same course. The material 1 in FIG. 1 to FIG. 3 is made of polyurethane threads 2 and polyester threads 3.

As shown in Figs. 1 and 2, in the material 1 of this embodiment, the polyurethane thread 2 is exposed from the first surface S1 and the second surface S2. The ratio (R1) of the polyurethane thread 2 exposed on the first surface S1 is greater than the ratio (R2) of the polyurethane thread 2 exposed on the second surface S2. In this way, the material 1 of this embodiment is configured so that the ratio (R1) of the polyurethane thread 2 exposed on the first surface S1 is greater than the ratio (R2) of the polyurethane thread 2 exposed on the second surface S2, so that when the material 1 is used so that the first surface S1 comes into contact with the application site, the polyurethane thread 2 easily comes into contact with the application site, and the anti-slip properties are excellent. Fig. 3 is a schematic external view for explaining the state in which the polyurethane thread B is overlapped on the same course in the polyester thread F and the polyurethane thread B. Reference numeral 4 indicates the portion where the polyurethane thread B overlaps. By knitting in this way, the polyurethane threads overlap each other to create a sense of unevenness, thereby improving the anti-slip properties.

In this embodiment, the proportion of polyurethane thread exposed on the first and second sides can be calculated by the following method. The proportion can be calculated by utilizing an automatic area ratio calculation function using an electron microscope on the front and back sides of the fabric, or a fabric photo taken at the same magnification can be printed out on paper, the relevant area only cut out, and the weight measured, and the weight ratio can be calculated. By at least one of these methods, the proportion of polyurethane thread exposed on the first side (R1) and the proportion of polyurethane thread exposed on the second side (R2) can be calculated and compared.

In addition, in this embodiment, the "application location" where the first surface of the material is used to come into contact is not particularly limited. The application location is appropriately selected depending on the use of the material. For example, if the material is a mattress pad, the application location is a bed mattress or a futon. If the material is a bath mat, the application location is a bathroom floor, etc. If the material is a table mat, the application location is a table, etc. If the material is a supporter, the application location is a person's upper arm, etc. If the material is a bag, the application location is the shoulder strap of the bag, etc. If the material is a chair, the application location is the seat, etc. If the material is a shoe, the application location is an insole, etc. In addition, the material may be an anti-slip tape provided on the inner waist part of the lower garment. In this case, the application location is an upper garment such as a shirt or underwear, etc. In the case of socks, it is partially placed on the inside to prevent slipping. In this way, the material of this embodiment can be used as various materials that require anti-slip properties. This allows the material to exhibit excellent anti-slip properties in the areas where it is applied, depending on the application.

In the material of this embodiment, the mixing ratio of polyurethane yarn is preferably 30% by mass or more, more preferably 20% by mass or more, relative to the material. In addition, the mixing ratio of polyurethane yarn is preferably 50% by mass or less, more preferably 40% by mass or less, relative to the material. By using a material having such a mixing ratio, the material is configured so that the ratio of polyurethane yarn (R1) on the first surface is greater than the ratio of polyurethane yarn (R2) on the second surface, and the amount of polyurethane yarn exposed on the first surface is easily adjusted to a certain amount or more. As a result, the material is likely to exhibit excellent anti-slip properties when the first surface is brought into contact with the application site. In addition, by setting the mixing ratio of polyurethane yarn to the above range, the material is likely to have a small basis weight. As a result, the obtained material is lightweight. Furthermore, by setting the mixing ratio of polyurethane yarn to the above range, the material is likely to exhibit the above anti-slip properties, and the mixing ratio of polyurethane yarn is easily suppressed, which improves processability and makes it easy to produce.

The total fineness of the polyurethane yarn is not particularly limited. For example, the total fineness of the polyurethane yarn is preferably 70 dtex or less, and more preferably 55 dtex or less. When the total fineness of the polyurethane yarn is within the above range, the material does not become too heavy as a fabric, the amount of polyurethane is appropriate, and the anti-slip properties are good. The lower limit of the total fineness of the polyurethane yarn is not particularly limited. For example, the lower limit of the total fineness is preferably 20 dtex or more, and more preferably 30 dtex or more. When the total fineness of the polyurethane yarn is within the above range, the contact area of the polyurethane yarn of the material increases, and the anti-slip properties are good.

The fibers constituting the other threads constituting the material of this embodiment are not particularly limited. For example, the fibers constituting the other threads include polyester fibers, polyamide fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polyvinyl chloride fibers, acetate fibers, cellulose fibers such as viscose rayon and cupra, natural plant fibers including cotton and hemp, and natural animal fibers including wool, cashmere and silk. Among these, it is preferable that the fibers constituting the other threads include polyester fibers, and it is preferable that the fibers include aromatic polyester fibers such as polyethylene terephthalate, polytrimethylene terephthalate and polybutylene terephthalate, and aliphatic polyester fibers such as polylactic acid and polyglycolic acid.

The total fineness of the other yarns is not particularly limited. As an example, the total fineness of the other yarns is preferably 110 dtex or less, and more preferably 84 dtex or less. Also, the total fineness of the other yarns is preferably 56 dtex or more, and more preferably 33 dtex or more. By having the total fineness of the other yarns within the above range, the material does not become too heavy in texture, the polyurethane blend ratio is increased, and the material has excellent anti-slip properties while remaining relatively light.

The number of filaments in the other threads is not particularly limited. As an example, the number of filaments in the other threads is preferably 24 or more, and more preferably 18 or more. Also, the number of filaments in the other threads is preferably 48 or less, and more preferably 36 or less. By having the number of filaments in the other threads within the above range, the material does not become too soft, and while being light, it is able to maintain a moderate sense of firmness.

The form of the yarn constituting the other yarn is not particularly limited. As an example, the form of the other yarn may be FDY (fully drawn yarn, full drawn yarn) or DTY (drawn textured yarn, drawn yarn).

Returning to the description of the entire material of this embodiment, the basis weight of the material is 100 g/ ^m2 or less, preferably 90 g/ ^m2 or less, and more preferably 80 g/ ^m2 or less. The basis weight of the material is preferably 60 g/ ^m2 or more, and more preferably 50 g/ ^m2 or more. If the basis weight of the material exceeds 100 g/ ^m2 , the material is heavy and difficult to handle. In addition, since the basis weight of the material is within the above range, the material is lightweight while maintaining sufficient anti-slip properties. In this embodiment, the basis weight can be measured in accordance with JIS L 1096 8.3.2 A method (2010).

The material of this embodiment is made of a warp knitted fabric in which multiple polyurethane yarns are arranged on the same course. That is, as shown in Figures 1 and 3, the polyurethane yarns exposed on the first surface in particular are multiple polyurethane yarns overlapping on the same course. As a result, the polyurethane yarns in the overlapping areas swell and are easily exposed to the outside. As a result, when the material is used so that the first surface is in contact with the application location, the polyurethane yarns are likely to come into contact with the application location. As a result, the material can exhibit excellent anti-slip properties based on the viscosity of the polyurethane yarns.

The knitting method (knitting structure) for constructing such a warp knitted fabric is not particularly limited. The knitting structure may be a weave structure in which multiple polyurethane threads can be arranged on the same course, and as a result, the proportion of polyurethane threads exposed on the first surface (R1) is greater than the proportion of polyurethane threads exposed on the second surface (R2). As an example, the knitting structure may be denby, half, atlas, satin, queen's cord, double denby, back half, double half, etc. Among these, the knitting structure of the material of this embodiment is preferably queen's cord. This makes it easy to arrange multiple polyurethane threads on the same course, and to configure the material so that the proportion of polyurethane threads exposed on the first surface (R1) is greater than the proportion of polyurethane threads exposed on the second surface (R2). As a result, the material is easy to exhibit excellent anti-slip properties while suppressing the polyurethane blend ratio. Furthermore, since the knitting structure is queen's cord, the material can be manufactured using two reeds. This makes it easy to manufacture the material so that the basis weight is small, and it is easy to reduce the weight. Queen's cord is a knitting structure that can be made using two reeds, and can be made by using the front reed to make chain stitches and the back reed to knit the plain ground structure. Therefore, by using queen's cord as the knitting structure, the material obtained has more exposed polyurethane yarn on the other side (second side) where the chain stitches are made than on the other side (second side) where the plain ground structure is knit.

The knitting machine for creating the above knitted structure is not particularly limited. For example, the knitting machine may be a tricot machine, a raschel machine, a double tricot machine, a double raschel machine, etc.

In this embodiment, "arranged on the same course" means arranging the raw yarn so that it is present on only one knitting needle used during knitting. In this case, even if the polyurethane yarn is arranged on the same course but with two or more needles skipped, this is included in the "material with multiple polyurethane yarns arranged on the same course" as referred to in this embodiment. As long as it is on the same course, polyurethane can be arranged with any number of needles skipped, but it is preferable not to skip any needles as this increases the surface area that comes into contact with the ground.

The obtained material is used so that the first surface comes into contact with the application area. This allows the material to exhibit excellent anti-slip properties. Specifically, the material of this embodiment has a static friction coefficient of 1.0 or more, more preferably 1.1 or more, in the lateral direction (i.e., the direction perpendicular to the course (well direction)) on the first surface. In this embodiment, the static friction coefficient can be measured in a dry state using the horizontal method of JIS P 8147 (2010), a test size of 90 mm x 60 mm, a weight of 1 kg, and cotton cloth (Kanakin No. 3) as the target fabric. In this embodiment, if the static friction coefficient is 1.00 or more, it can be said that the anti-slip properties are excellent.

Furthermore, the material of this embodiment is less likely to experience a decrease in anti-slip properties over time. Specifically, when a wear test is performed on the first surface of the material, the static friction coefficient (C1) in the lateral direction on the first surface before the wear test and the static friction coefficient (C2) in the lateral direction on the first surface after the wear test are both preferably 1.00 or more, and more preferably 1.05 or more. Furthermore, the ratio (C2/C1) of the static friction coefficient (C1) to the static friction coefficient (C2) is preferably 0.90 or more, more preferably 0.95 or more, and even more preferably 1.00 or more. In this embodiment, the wear test can be performed using a friction tester type II described in JIS L 0849 (2013) with a load of 2N and 500 friction cycles.

In particular, the material of this embodiment can have a static friction coefficient (C2) after the abrasion test that is greater than the static friction coefficient (C1) before the abrasion test. That is, the ratio (C2/C1) can be 0.90 or more. This is thought to be due to the fact that, since the polyurethane thread is exposed on the first surface, when the first surface is pressed against the application site during the abrasion test, the surface shape of the polyurethane exposed on the first surface is somewhat crushed, increasing the contact area of the polyurethane thread that comes into contact with the application site. In this way, the material of this embodiment is configured so that more polyurethane thread is exposed on the first surface, and therefore can maintain excellent anti-slip properties even after the abrasion test, and in some cases can exhibit better anti-slip properties than before the abrasion test. Therefore, the material is suitable for long-term repeated use.

Furthermore, the material of this embodiment is unlikely to lose its anti-slip properties over time, even when it is washed repeatedly. Specifically, when the material is washed 10 times, the ratio (C4/C3) of the static friction coefficient in the lateral direction on the first surface before the washing process (C3) to the static friction coefficient in the lateral direction on the first surface after the washing process (C4) is preferably 0.90 or more, and more preferably 1.00 or more. In this embodiment, the washing process can be performed under the conditions of JIS L 1930 (2014) C4M method, line drying 10 times.

In particular, the material of this embodiment can have a static friction coefficient (C4) after washing processing that is greater than the static friction coefficient (C3) before washing processing. That is, the ratio (C4/C3) can be 0.90 or more. It is more preferable that the ratio (C4/C3) is 1.00 or more. This is thought to be due to the fact that, since the polyurethane thread is exposed on the first surface, when washing processing is performed, the surface shape of the polyurethane exposed on the first surface is somewhat crushed, and the contact area of the polyurethane thread that comes into contact with the application part increases. In this way, the material of this embodiment is configured so that more polyurethane thread is exposed on the first surface, so that it can maintain excellent anti-slip properties even after washing processing and can exhibit better anti-slip properties than before washing processing. Therefore, the material is suitable for long-term repeated use.

The above describes one embodiment of the present invention. The present invention is not particularly limited to the above embodiment. Note that the above embodiment mainly describes an invention having the following configuration.

(1) A material having a first surface and a second surface opposite to the first surface, the material being made of a warp knitted fabric in which a plurality of polyurethane yarns are arranged on the same course, the material having a basis weight of 100 g/ ^m2 or less, and the proportion (R1) of the polyurethane yarns exposed on the first surface being greater than the proportion (R2) of the polyurethane yarns exposed on the second surface.

According to this configuration, the material has a basis weight of 100 g/ ^m2 or less and is lightweight. In addition, while the material is lightweight, the ratio (R1) of the polyurethane yarn exposed on the first surface is greater than the ratio (R2) of the polyurethane yarn exposed on the second surface, so that the material has excellent anti-slip properties for the application area. Furthermore, in order to exhibit the above-mentioned anti-slip properties, the material is easy to suppress the mixing ratio of the polyurethane yarn, which can improve processability and is easy to produce.

(2) The material described in (1), in which the polyurethane yarn content is 30% by mass or more of the material.

With this configuration, the material is lightweight and exhibits excellent anti-slip properties, and also has excellent processability.

(3) The material according to (1) or (2), wherein the warp knitted fabric has a Queen's cord structure.

With this configuration, the material is easily configured so that the proportion of polyurethane thread exposed on the first surface (R1) is greater than the proportion of polyurethane thread exposed on the second surface (R2). As a result, the material is more likely to exhibit excellent anti-slip properties while keeping the polyurethane content low.

(4) A material described in any one of (1) to (3), in which the coefficient of static friction in the lateral direction on the first surface is 1.00 or more.

With this configuration, the material has better slip resistance in the area where it is applied.

(5) A material according to any one of (1) to (4), in which, when an abrasion test is performed on the first surface, the static friction coefficient (C1) in the lateral direction on the first surface before the abrasion test and the static friction coefficient (C2) in the lateral direction on the first surface after the abrasion test are both 1.00 or more, and the ratio (C2/C1) of the static friction coefficient (C1) to the static friction coefficient (C2) is 0.90 or more.

With this configuration, the material has better anti-slip properties in the areas where it is applied, and the anti-slip properties are less likely to decrease over time.

(6) A material according to any one of (1) to (5), in which the ratio (C4/C3) of the coefficient of static friction in the lateral direction on the first surface before the washing process (C3) to the coefficient of static friction in the lateral direction on the first surface after the washing process (C4) is 0.90 or more when the material is washed 10 times.

The present invention will be explained in more detail below with reference to the following examples. The present invention is not limited to these examples. Unless otherwise specified, "%" means "% by mass" and "parts" means "parts by mass."

In the following Examples and Comparative Examples, various evaluations of each material were carried out by the following methods.
(1) Total Fineness The total fineness was determined by measuring the corrected fineness according to the method shown in JIS L 1013 (2010) 8.3.1 B method.
(2) Number of filaments Calculated based on the method of JIS L 1013 (1999) 8.4.
(3) Basis Weight The basis weight was measured in accordance with JIS L 1096 8.3.2 Method A (2010).
(4) Exposed ratio of polyurethane The fabric photograph taken with an electron microscope at the same magnification was printed out on paper, and only the relevant portion was cut out and weighed. The ratio of the polyurethane yarn exposed on the first side (R1) and the ratio of the polyurethane yarn exposed on the second side (R2) were calculated and compared.
(5) Static Friction Coefficient The static friction coefficient was measured by the horizontal method of JIS P 8147 (2010), with a test size of 90 mm x 60 mm, a weight of 1 kg, and a cotton cloth (Kanakin No. 3) as the target cloth, under dry conditions. A static friction coefficient of 1.0 or more was determined to be excellent in anti-slip properties.
(6) Abrasion test The abrasion test was performed using a type II friction tester described in JIS L 0849 (2013) under the conditions of a load of 2 N and 500 friction cycles.
(7) Laundry Treatment The laundry treatment was carried out according to JIS L 1930 (2014) C4M method, hanging and drying 10 times.

Example 1
A polyester yarn (total fineness 56T, filament count 18f, blend ratio 60%) and a polyurethane yarn (total fineness 55T, blend ratio 40%) were used to knit a warp knitted fabric (Queen's Cord) using a two-reed tricot knitting machine. After that, the fabric was scoured in a continuous machine according to the usual method, and then finished in a pin tenter at a chamber temperature of 190°C to produce a material. The weight of the obtained material was 66 g/ ^m2 .

<Examples 2 to 3>
Materials were prepared in the same manner as in Example 1, except that the conditions were changed to those shown in Table 1.

<Comparative Example 1>
Polyester yarn (total fineness 84T) was used to make a beam with a warping machine, which was then woven with a water jet room to make a fabric, which was then scoured in a continuous machine according to the usual method, and the fabric was finished with a pin tenter at a chamber temperature of 190°C to produce a woven fabric (flat knit), and a urethane resin was dot-printed on the surface of the product. The basis weight of the obtained material was 100 g/ ^m2 .

<Comparative Example 2>
A polyester yarn (total fineness 56T) was used to knit a warp knitted fabric (Denby) using a tricot knitting machine. After that, the fabric was scoured in a continuous machine according to the usual method, and then finished in a pin tenter at a chamber temperature of 190°C to produce a material. The basis weight of the obtained material was 80 g/ ^m2 .

<Comparative Example 3>
A single circular knitting machine was used to knit a circular knitted fabric (plain stitch) using polyester yarn (total fineness 84T, blending ratio 90%) and polyurethane yarn (total fineness 22T, blending ratio 10%). After that, the fabric was scoured in a continuous machine according to the usual method, and then finished in a pin tenter at a chamber temperature of 190°C to produce a material. The basis weight of the obtained material was 140 g/ ^m2 .

<Comparative Example 4>
A polyester yarn (total fineness 33T, filament count 36f, blend ratio 80%) and a polyurethane yarn (total fineness 33T, blend ratio 200%) were used to knit a fabric consisting of a warp knitted fabric (double denby) using a three-reed tricot knitting machine. After that, following the usual method, the fabric was scoured using a continuous machine, and then finished using a pin tenter at a chamber temperature of 190°C to produce a material. The basis weight of the obtained material was 190 g/ ^m2 .

The materials obtained in the above examples and comparative examples were measured for the static friction coefficient, the static friction coefficient before and after the abrasion test, and the static friction coefficient before and after the washing treatment according to the above evaluation method. The results are shown in Table 1.

As shown in Table 1, the materials of Examples 1 to 3 of the present invention had excellent processability, were easy to produce, and were lightweight with a basis weight of 100 g/ ^m2 or less. In addition, the materials of Examples 1 to 3 had a large static friction coefficient of the first surface that contacts the application area, and exhibited excellent anti-slip properties. Furthermore, the static friction coefficient of the materials of Examples 1 to 3 did not decrease after abrasion tests and washing treatments, and excellent anti-slip properties were maintained.

1 Material 2 Polyurethane thread 3 Polyester thread 4 Area where polyurethane thread overlaps S1 First surface S2 Second surface F Polyester thread B Polyurethane thread

Claims

a material having a first surface and a second surface opposite the first surface;
It is made of a warp knitted fabric in which multiple polyurethane yarns are arranged on the same course,
The basis weight is 100 g/ m2 or less,
A material, wherein a proportion (R1) of the polyurethane yarns exposed on said first side is greater than a proportion (R2) of the polyurethane yarns exposed on said second side.
The material according to claim 1, wherein the polyurethane yarn content is 30% by mass or more of the material.
The material according to claim 1 or 2, wherein the warp knit fabric has a structure of queens cord.
The material according to claim 1 or 2, wherein the coefficient of static friction in the lateral direction on the first surface is 1.00 or more.
When a wear test is performed on the first surface, a static friction coefficient (C1) in a lateral direction on the first surface before the wear test and a static friction coefficient (C2) in a lateral direction on the first surface after the wear test are both 1.00 or more;
3. The material according to claim 1, wherein the ratio (C2/C1) of the static friction coefficient (C1) to the static friction coefficient (C2) is 0.90 or more.
The material according to claim 1 or 2, wherein the ratio (C4/C3) of the static friction coefficient in the lateral direction on the first surface before the washing process (C3) to the static friction coefficient in the lateral direction on the first surface after the washing process (C4) is 0.90 or more when the material is washed 10 times.