JP4386444B2 - Three-dimensional solid knitted fabric capable of expanding the distance between the upper knitted fabric and the lower knitted fabric, and a method for producing the same - Google Patents

Description

  The present invention relates to a three-dimensional solid knitted fabric in which an upper knitted fabric and a lower knitted fabric that are spaced apart from each other are connected by connecting yarns, and in particular, the distance between the upper knitted fabric and the lower knitted fabric is greatly increased, and a liquid or powder Further, the present invention relates to a three-dimensional solid knitted fabric used as a base material such as an air bag, a rubber boat, an air mat, and a water bed, which is used by being filled with gas or the like.

  For three-dimensional solid knitted fabrics, two surfaces obtained by using a warp knitting machine having two rows of knitting needles, forming knitted fabrics with ground yarns at each knitting needle row, and knitting these knitted fabrics with connecting yarns A three-dimensional warp knitted fabric is well known.

  As a technique using such a three-dimensional solid knitted fabric, Patent Document 1 discloses a technique using an airbag made of a three-dimensional solid knitted fabric at a portion constituting a simple bathtub.

Patent Document 2 proposes a knitting structure, a knitting method, and a knitting apparatus that can be used as a reinforcing material for a bag body when manufacturing an airtight bag body used for an air jack, an airbag, or the like in a flat knitting machine. Yes. These techniques are widely known as applying the characteristics of a three-dimensional solid knitted fabric. However, these disclosed three-dimensional three-dimensional knitting methods knitting front and rear knitted fabrics through two rows of needle beds, and alternately connecting a plurality of insertion yarns to the front and rear knitted fabrics, Knitting. The distance between the front and back knitted fabrics is determined by the interval between the two rows of needle beds, and the upper limit is about 90 mm due to the mechanism of the knitting machine. Deviation occurred in the upper and lower knitted fabrics, and the degree of processing was high. Moreover, in order to obtain a thicker cushion body, Patent Document 3 discloses a technique in which several layers of other cushion bodies are superimposed on a three-dimensional solid knitted fabric.
JP 2001-37662 A JP-A-10-195740 JP 2002-325657 A

  The present invention has been made in view of such a technical background, and can be processed like a normal knitted fabric using a conventional knitting machine at the time of various processing to a knitted fabric, and between upper and lower knitted fabrics. To provide a three-dimensional solid knitting method and a three-dimensional solid knitted fabric that maintain the thickness immediately after knitting and use the distance between the upper and lower knitted fabrics dramatically at the stage of final product. With the goal.

  As a result of intensive studies to solve such problems, the present inventors have solved, melted, fused, as a connecting yarn holding yarn that partially inserts and fixes the connecting yarn that connects the upper and lower knitted fabrics to the knitted fabric. Use fibers that have either decomposition or embrittlement properties, and stop yarns should be dissolved, melted, decomposed, or embrittled after being knitted with a structure that does not partially connect the upper and lower knitted fabrics. After removing the connecting yarn holding yarn and maintaining the distance between the upper and lower knitted fabrics by the stop yarn, the upper and lower knitting are performed by eliminating the connection of the stop yarn at the stage of the final product after each processing step. The inventors have found that the distance between the grounds can be dramatically increased and have reached the present invention. In order to achieve the above object, the present invention provides the following means.

  [1] In a three-dimensional three-dimensional knitted fabric in which an upper knitted fabric and a lower knitted fabric arranged apart from each other are connected by a connecting yarn and a stop yarn, the connecting yarn is placed in the upper knitted fabric and the lower knitted fabric. The connecting yarn holding yarn that is partially inserted and held has the properties of dissolution, melting, decomposition, and embrittlement, and the connecting yarn is not partly knitted into the ground structure and is used as the connecting yarn holding yarn. A three-dimensional three-dimensional knitted fabric knitted with a structure to be inserted, and further, the stop yarn partially connects an upper knitted fabric and a lower knitted fabric.

  [2] The ground yarn and the connecting yarn constituting the three-dimensional knitted fabric are composed of a synthetic fiber multifilament of 150 to 1000 dtex, and the connecting yarn holding yarn is any of melting, melting, decomposition, and embrittlement of 50 to 700 dtex The three-dimensional solid knitted fabric according to item 1 above, which is characterized by comprising fibers having the following properties:

  [3] The connection yarn holding yarn is removed by at least one of dissolution, melting, decomposition, and embrittlement, and the connection that partially connects the upper knitted fabric and the lower knitted fabric by the stop yarn is eliminated. By this, the distance between the upper knitted fabric and the lower knitted fabric that are arranged apart from each other is increased by twice or more than before the connection yarn holding yarn is removed and the stop yarn is no longer connected. 3D solid knitted fabric according to 1 or 2

  [4] The three-dimensional solid knitted fabric according to any one of items 1 to 3, wherein the connecting yarn holding yarn is made of 50-700 dtex water-soluble fiber.

  [5] The preceding items 1 to 4, wherein the stop yarn is cut by applying tension to the stop yarn, and the connection by the stop yarn that partially connects the upper knitted fabric and the lower knitted fabric is eliminated. Three-dimensional solid knitting.

  [6] In a three-dimensional three-dimensional knitted fabric in which an upper knitted fabric and a lower knitted fabric arranged apart from each other are connected by a connecting yarn and a stop yarn, the connecting yarn holding yarn that holds the connecting yarn in the upper and lower knitted fabrics. The distance between the upper knitted fabric and the lower knitted fabric, which are spaced apart from each other, can be maintained by removing any of the above by dissolving, melting, decomposing, or embrittlement, and eliminating the connection of the stop yarn. A method for producing a three-dimensional solid knitted fabric characterized in that the yarn is removed and spreads more than twice as long as the stop yarn is no longer connected.

  According to the invention of [1], in the three-dimensional solid knitted fabric in which the upper knitted fabric and the lower knitted fabric that are arranged apart from each other are connected by the connecting yarn, the connecting yarn holding yarn that holds the connecting yarn is dissolved and melted. It consists of a connecting yarn holding yarn having any of the properties of decomposition, embrittlement, and the connecting yarn is knitted with a structure that is inserted into the connecting yarn holding yarn without being knitted into the ground structure. If the yarn holding yarn disappears by any of the methods of dissolution, melting, decomposition, and embrittlement, there is no connection between the upper knitted fabric and the lower knitted fabric in a state where a part of the connecting yarn is not held and is bent. It can be in the form. Further, in this embodiment, since the upper knitted fabric and the lower knitted fabric are partially connected by the stop yarn, the upper knitted fabric and the lower knitted fabric are not connected by the stop yarn after all the processing steps. If a force is applied in the direction in which the upper and lower knitted fabrics are separated, the bent connecting yarn is stretched, and the distance between the upper knitted fabric and the lower knitted fabric can be increased.

  According to the invention of [2], since the ground yarn and the connecting yarn constituting the three-dimensional knitted fabric are composed of 150 to 1000 dtex synthetic fiber multifilament, the upper knitted fabric and the lower knitted fabric have sufficient knitting density. The strength is ensured, and the connecting yarn can connect the upper and lower knitted fabrics with appropriate strength. In addition, since the connecting yarn holding yarn is made of a fiber having any property of dissolution, melting, decomposition, and embrittlement of 50 to 700 dtex, for example, the connecting yarn holding yarn is not dissolved in the hot water by passing it through warm water. The distance between the upper knitted fabric and the lower knitted fabric is increased by the length of the bent connecting yarn between the connecting yarns knitted in the ground yarn when the connection by the stop yarn is lost.

  According to the invention of [3], the connecting portion between the connecting yarn holding yarn and the connecting yarn is eliminated by removing the connecting yarn holding yarn by at least one of dissolution, melting, decomposition, and embrittlement. The number of connecting yarns of the number of connecting portions can be kept bent without being held. Thus, unless a strong force is applied in the direction in which the upper and lower knitted fabrics are spread, each processing step can be performed while maintaining the knitted thickness, and suitable workability can be obtained. Furthermore, in the last step, the connection yarn holding yarn is removed from the distance between the upper knitted fabric and the lower knitted fabric by eliminating the connection that partially connects the upper knitted fabric and the lower knitted fabric of the stop yarn. It can be expanded twice or more than before.

  According to the invention of [4], since the connecting yarn holding yarn is composed of 50-700 dtex water-soluble fiber, the connecting yarn holding yarn can be easily dissolved in water by being immersed in water.

  According to the invention of [5], the stop yarn can be cut by applying tension to the stop yarn, and the connection of the stop yarn that partially connects the upper knitted fabric and the lower knitted fabric can be eliminated. The distance between the upper knitted fabric and the lower knitted fabric is increased by the bent length between the connecting yarns knitted into the yarn.

  According to the invention of [6], in the three-dimensional solid knitted fabric in which the upper knitted fabric and the lower knitted fabric arranged apart from each other are connected by the connecting yarn, the connecting yarn is held in the upper and lower knitted fabrics. By removing the connecting yarn holding yarn by any of the methods of melting, melting, decomposing, and embrittlement, and eliminating the connection of the stop yarn, the distance between the upper knitted fabric and the lower knitted fabric arranged apart from each other can be increased. Further, it is possible to provide a method for manufacturing a three-dimensional solid knitted fabric in which the connecting yarn holding yarn is removed, and finally the unfolding of the stop yarn is expanded more than twice.

  Next, an embodiment of a three-dimensional solid knitted fabric according to the present invention will be described with reference to the drawings. FIG. 1 schematically illustrates a three-dimensional solid knitted fabric according to this embodiment. The three-dimensional solid knitted fabric 1 includes a connecting yarn 4 between an upper knitted fabric 2 and a lower knitted fabric 3 that are spaced apart from each other. Connected by The knitted fabric constituting the upper knitted fabric 2 and the lower knitted fabric 3 is knitted by the ground yarn 5 and the connecting yarn holding yarn 6. The connecting yarn 4 is a knitted structure 7 inserted into the sinker loop of the connecting yarn holding yarn 6. The connecting yarn holding yarn 6 has a property of being dissolved or decomposed and lost when heated or passed through warm water. The connecting yarn 7 inserted in the sinker loop of the dissolving connecting yarn holding yarn 6 is bent and maintains the state as it is, and the connecting yarn 8 knitted on the undissolved ground yarn 5 is fixed to the upper and lower knitted fabrics as a connecting point 9. Has been. The distance between the upper knitted fabric 2 and the lower knitted fabric 3 to be spread is determined by the length of the connecting yarn between the connecting points 9 knitted on the undissolved ground yarn 5.

  Usually, after knitting in the state of FIG. 1, after various processing, the distance between the upper knitted fabric and the lower knitted fabric is increased. FIG. 2 shows a state in which the connecting yarn holding yarn 6 of the three-dimensional solid knitted fabric of this embodiment is melted and the stop yarn (not shown) is pulled off to widen the distance between the upper knitted fabric 2 and the lower knitted fabric 3. It is a schematic depiction.

  In the present invention, the connecting yarn holding yarn for holding the connecting yarn has any of the properties of dissolution, melting, decomposition, and embrittlement. For example, water-soluble vinylon yarn (vinyl hydroxide alcohol), low melting point polypropylene yarn And polylactic acid yarn. Among these, water-soluble fibers are preferable because they are easy to handle. The fineness may be 50 to 700 dtex.

  The upper knitted fabric 2 and the lower knitted fabric 3 are knitted with a ground yarn 5, a connecting yarn holding yarn 6, and a stop yarn (not shown). The structure structure of the three-dimensional knitted fabric is not particularly limited, and the upper and lower ground structures may be the same knitted structure or different knitted structures. For example, any structure may be used as long as the upper knitted fabric and the lower knitted fabric have a chain structure, and a connecting yarn and a stop yarn are knitted or inserted between the upper and lower ground structures. The ground yarn 5 and the connecting yarn are preferably composed of 150 to 1000 dtex synthetic fiber multifilament. Synthetic fiber multifilaments are used when they are used widely separated, for example, in rubber boats and simple bathtubs, where strength and durability are required. Since it is necessary to be able to withstand processing, it is preferable not to use natural fibers or the like. As the synthetic fiber multifilament, a multifilament such as polyamide, polyester, vinylon, or aramid is preferable, and the fiber cross section may be a round cross section, a flat or irregular cross section. Further, a thin thread of less than 150 dtex is not preferable because the strength is weakened. Thick yarns exceeding 1000 dtex are not preferable because knitting becomes difficult. More preferably, it consists of a synthetic fiber multifilament of 200 to 500 dtex.

  After the connecting yarn holding yarn is dissolved, melted, decomposed, or embrittled and no longer holds the connecting yarn, the upper knitted fabric is joined by the connecting yarn and the stop yarn knitted in the upper knitted fabric and the lower knitted fabric. The lower knitted fabric is connected, and the next processing is performed while maintaining the distance of FIG. As for the connection between the upper knitted fabric and the lower knitted fabric, the distance between the upper knitted fabric and the lower knitted fabric is increased when the connection by the stop yarn is lost in the final process. The fiber type of the stop yarn is not particularly limited, but it breaks as much as the connecting yarn holding yarn when the yarn having weak tensile strength or the connecting yarn holding yarn is subjected to any of the processes of dissolution, melting, decomposition, and embrittlement. Examples include water-soluble vinylon yarns (vinyl hydroxide alcohol), polypropylene yarns having a low melting point, polylactic acid yarns, etc., which are thicker than the connecting yarn holding yarns. If the tensile strength is 9.8 N / 1 or less, the stop yarn can be pulled off while separating the upper knitted fabric and the lower knitted fabric, and the state shown in FIG. 2 can be obtained.

  The knitting machine according to the present invention is preferably a knitting machine having a 9-32 gauge double row needle bed. A coarse gauge of less than 9 gauge is not preferred because the density is coarse and the dimensional stability is poor. Further, a fine gauge exceeding 32 gauge is not preferable because the yarn becomes thin and the strength becomes weak. More preferably, a double raschel machine of 18 to 28 gauge double-row needle bed is preferable. The knitting density is preferably knitted to a density of 15 to 40 courses / inch. More preferably, 20 to 30 courses / inch is preferable.

  Further, as shown in FIG. 1, the connecting yarns are a structure 7 inserted into the sinker loop of the connecting yarn holding yarn without being knitted into the ground structure, and a structure 8 knitted into the ground structure. In FIG. b. c. The part is the part where the connecting thread is inserted and held in the sinker loop of the soluble connecting thread holding thread, and the connecting thread retaining thread dissolves and disappears when heated or passed through warm water. , A state in which a retaining thread (not shown) is pulled and widened in the vertical direction is shown. In the present invention, after the connecting yarn holding yarn is dissolved and lost, the connecting yarn 4 remains in the bent state as shown in FIG. 1 unless a force is applied in the vertical direction. In this way, a filler such as air is injected into the interior, and the retaining thread is pulled out and expanded in the vertical direction.

  The fabric knitted in this way, for example, in the case of a fabric for an air mat, is first washed with warm water to dissolve the water-soluble connecting yarn holding yarn, dried with a dryer, and then the upper knitted fabric 2 and The outer surface of the lower knitted fabric 3 is shielded with a concealing film, cut into the size of an air mat, the peripheral portion is processed so that air does not leak, and air is injected to obtain an air mat. In this way, an air mat showing a stable pressure distribution can be obtained.

Next, specific examples of the present invention will be described.
<Example 1>
With the knitting structure shown in FIG. 3, a three-dimensional solid knitted fabric having the following specifications was obtained.
Knitting machine: Double raschel machine (22 gauge / inch, distance between hooks 6 mm), Wale density: 22 / inch, course density 25.7 / inch, Knitting yarn for outer knitted fabric (L1 L2): 235 dtex / 24f nylon BCF multifilament, knitted yarn of back knitted fabric (L7 L8): 235 dtex / 24f nylon BCF multifilament, connecting yarn (L5): 280 dtex / 48f polyester multifilament, connecting yarn holding yarn (L3 L6): 110 dtex / 30f dissolved in water Resin Vinylon, Retaining thread (L4): 40/2 Polyester 65% Rayon 35% (Tensile strength 9.1N / 1), Surface knitted fabric structure: Quinns cord, Back knitted fabric structure: Quinns cord, thickness A 6 mm three-dimensional solid knitted fabric was obtained. Next, the fabric of the three-dimensional knitted fabric was subjected to a step of washing for 30 minutes with warm water at 80 ° C. and then dried and set at 150 ° C. for 3 minutes. When the front knitted fabric and the back knitted fabric were held by hand and pulled with a weak force enough to pull off the retaining thread, the distance between the front knitted fabric and the back knitted fabric could be 60 mm.

<Example 2>
Except that the knitting structure shown in FIG. 4 was used, a three-dimensional three-dimensional knitted fabric having a thickness of 6 mm was obtained in the same manner as in Example 1 and pulled with a weak force enough to pull off the stop yarn. The ground distance could be 80 mm.

<Comparative Example 1>
A three-dimensional solid knitted fabric having a thickness of 6 mm was obtained in the same manner as in Example 1 except that the retaining thread (L4) was changed to 30/2 polyester 65% rayon 35% (tensile strength 28N / 1). As a result, when the pulling yarn was pulled with such a weak force as to pull off the stop yarn, the distance between the front knitted fabric and the back knitted fabric could not be increased without being pulled.

It is a schematic sectional drawing of the three-dimensional solid knitted fabric which concerns on one Embodiment of this invention. It is a schematic sectional drawing when the distance of the front knitted fabric and back knitted fabric of the three-dimensional solid knitted fabric of FIG. 1 is expanded. It is a knitting | organization organization chart of the three-dimensional solid knitted fabric which concerns on one Embodiment of this invention. It is a knitting | organization organization chart of the three-dimensional solid knitted fabric which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Three-dimensional solid knitted fabric 2 ... Upper knitted fabric 3 ... Lower knitted fabric 4 ... Connecting yarn 5 ... Ground yarn 6 ... Connecting yarn holding yarn 7 ... Connecting yarn is a sinker Knitting structure inserted into the loop (connecting yarn inserted into the sinker loop)
8 ... Knitting structure in which connecting yarn is knitted into ground yarn (connected yarn knitted into ground yarn)
9 ··· Connection point L1 L2 ·· Knitting yarn for front knitted fabric L7 L8 · · Knitting yarn for back knitted fabric L3 L6 · · Connection yarn holding yarn L4 · · Stop yarn L5 · · Connection yarn

Claims (6)

  In a three-dimensional solid knitted fabric in which an upper knitted fabric and a lower knitted fabric that are spaced apart from each other are connected by a connecting yarn and a stop yarn, the connecting yarn is partially in the upper knitted fabric and the lower knitted fabric. The connecting yarn holding yarn to be inserted and held has properties of melting, melting, decomposition, and embrittlement, and the connecting yarn is inserted into the connecting yarn holding yarn without being partially knitted into the ground structure. A three-dimensional three-dimensional knitted fabric characterized by being knitted with a structure and further, the stop yarn partially connecting an upper knitted fabric and a lower knitted fabric.   The ground yarn and the connecting yarn constituting the three-dimensional knitted fabric are made of synthetic fiber multifilament of 150 to 1000 dtex, and the connecting yarn holding yarn has any property of dissolution, melting, decomposition, and embrittlement of 50 to 700 dtex. The three-dimensional solid knitted fabric according to claim 1, wherein the three-dimensional solid knitted fabric is characterized by comprising fibers having the same.   The connection yarn holding yarn is removed by at least one of the methods of dissolution, melting, decomposition, embrittlement, and by eliminating the connection that partially connects the upper knitted fabric and the lower knitted fabric by the stop yarn, The distance between the upper knitted fabric and the lower knitted fabric, which are arranged apart from each other, is increased by two times or more than before the connection yarn holding yarn is removed and the stop yarn is no longer connected. 3D solid knitted fabric as described in 2   The three-dimensional solid knitted fabric according to any one of claims 1 to 3, wherein the connecting yarn holding yarn is made of 50-700 dtex water-soluble fiber.   The tertiary according to any one of claims 1 to 4, wherein the stop yarn is cut by applying tension to the stop yarn, and the connection by the stop yarn that partially connects the upper knitted fabric and the lower knitted fabric is eliminated. Original three-dimensional knitting.   In a three-dimensional three-dimensional knitted fabric in which an upper knitted fabric and a lower knitted fabric arranged apart from each other are connected by a connecting yarn and a stop yarn, the connecting yarn holding yarn that holds the connecting yarn in the upper and lower knitted fabrics is dissolved, The connected yarn holding yarn removes the distance between the upper knitted fabric and the lower knitted fabric that are spaced apart from each other by removing them by any method of melting, decomposition, and embrittlement, and eliminating the connection of the stop yarns. And a method for producing a three-dimensional solid knitted fabric characterized in that it is spread twice or more than before the connection of the stop yarn is lost.

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