JP4789342B2 - Cushion material, sheet and method of filing pile yarn - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention is applied to a vehicle seat such as an automobile or a train, an office chair, or a furniture chair (seat). Cushion material made of three-dimensional solid knitted fabric used, sheet provided with the cushion material, and pile yarn flocking method About.
[0002]
[Prior art]
2. Description of the Related Art In recent years, a vehicle seat using a net material (three-dimensional solid knitted fabric) having a three-dimensional structure that is thin, can exhibit high cushioning properties, has a large number of voids, and has excellent air permeability is known. A pair of ground knitted fabrics that are spaced apart from each other are joined together with a number of connecting yarns to form a truss structure (three-dimensional structure), which is an elastic structure that is difficult to sag, breathability, and body pressure dispersion It is excellent in characteristics, shock absorption characteristics and the like, and can exhibit characteristics close to those of a highly elastic polyurethane foam that is widely used as a cushioning material while being thin.
[0003]
[Problems to be solved by the invention]
Although the three-dimensional solid knitted fabric has the characteristics as described above, it is composed of a pair of ground knitted fabrics and a connecting yarn disposed by reciprocating between the ground knitted fabrics. For use in the above, simply cutting to a predetermined size makes the yarns and fibers constituting them easy to fray, looks bad, and is inconvenient to handle. Further, in order to obtain a desired spring property (cushioning property), a monofilament yarn is often used as the connecting yarn, and a yarn having a thickness of about 167 to 1100 dtex is used. Therefore, when this connecting thread protrudes from the cut surface and touches the human body, the human body feels hard and feels bad.
[0004]
Therefore, the appearance of the end portion of the three-dimensional solid knitted fabric, that is, the design is improved, the tactile sensation is improved, and furthermore, the frictional force is improved to eliminate the slipperiness. It has been desired to improve the properties and the like. For this reason, conventionally, in order to improve the appearance of the terminal portion and improve the convenience of handling, the terminal portion is covered with a skin material and both are sewn. However, the sewing work is time consuming and troublesome, and the cost required for the work is high. Moreover, since it coat | covers with a skin material, the part also increases in weight.
[0005]
On the other hand, in order to improve the design, tactile sensation, frictional force, etc. of the three-dimensional solid knitted fabric, the epidermis is designed not only to the above-mentioned terminal part, but also to a predetermined pattern or character on an arbitrary part such as near the center. Although a material may be attached, the three-dimensional solid knitted fabric has a thickness of at least about 5 mm to 30 mm, and it is very difficult to attach the material by sewing. Actually, the total thickness of the parts to be sewn that can be sewn is up to about 25 mm, and when the three-dimensional solid knitted fabric has a thickness greater than that, it is impossible to attach the skin material by sewing. there were.
[0006]
Also, a processing technique (electrodeposition processing) that applies an adhesive to the three-dimensional solid knitted fabric in advance, charges static electricity to the thin-pile pile yarn, adheres to the three-dimensional solid knitted fabric, and applies a pattern, characters, etc. (Flocky processing) is also known. In this case, however, a large number of fine pile yarns float and there is a problem that an operator can easily suck them.
[0007]
The present invention has been made in view of the above, and it is possible to improve the designability, touch feeling, frictional force, etc., and the processing is performed by welding a very light, fine-pile pile yarn at an arbitrary site or terminal portion. Three-dimensional knitted fabric Cushion material comprising, a seat provided with the cushion material It is an issue to provide. In addition, the present invention greatly suppresses the amount of floating during the work of this fine-pile pile yarn, and very easily attaches to an arbitrary part or terminal portion, and the design property, tactile sensation, frictional force of the three-dimensional solid knitted fabric To the three-dimensional solid knitting that can improve the How to plant pile yarn The issue is to provide.
[0008]
[Means for Solving the Problems]
In order to solve the above-described problems, in the present invention according to claim 1, a three-dimensional solid knitted fabric formed by connecting a pair of ground knitted fabrics spaced apart from each other with a connecting yarn. Cushioning material for seats Because
It has a concave line formed so as to be in a semi-collapsed state by vibration welding at the boundary between the center of the seating surface and each side, and pile yarn is planted by welding on the surface of the concave line. Cushion material I will provide a.
In the present invention described in claim 2, The cushion material according to claim 1 is used for a seat cushion part. I will provide a.
In this invention of Claim 3, it forms by couple | bonding a pair of ground knitted fabrics spaced apart from each other with a connecting yarn. Cushion material for seats made of three-dimensional solid knitted fabric A method of planting pile yarn,
On the surface of the concave line formed so as to be semi-crushed by vibration welding at the boundary between the center of the seat surface and each side, A fabric in which pile yarn is woven between the ground yarns constituting the base fabric By laminating and applying welding means A part of the pile yarn In concave line Ground knitted fabric as well as Weld and fix to the connecting thread near the part, and then peel off the fabric base fabric, In concave line Remains pile yarn welded and fixed to the knitted fabric and the connecting yarn in the vicinity of the part Let me It is characterized by flocking Pile yarn Provides a method of flocking.
In this invention of Claim 4, In the step of laminating the fabric on the surface of the concave line, the fabric yarn is laminated so that the back side of the pile yarn is not in contact with the protruding side, and in the step of applying the welding means, the pile yarn woven between the ground yarns The pile yarn according to claim 3, wherein a bent portion located on the back side of the base fabric is welded and fixed to the ground knitted fabric in the concave line and the connecting yarn in the vicinity of the portion. Provides a method of flocking.
In the present invention described in claim 5, The pile yarn according to claim 3 or 4, wherein a moquette is used as the fabric. Provides a method of flocking.
In the present invention described in claim 6, The pile yarn according to any one of claims 3 to 5, wherein vibration welding means is used as the welding means. Provides a method of flocking.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in more detail with reference to the drawings. First, an example of the structure of the main body part of the three-dimensional solid knitted fabric 10 to which the present invention is applied will be described with reference to FIGS. As shown in these drawings, the three-dimensional solid knitted fabric 10 reciprocates between the pair of ground knitted fabrics 11 and 12 and the pair of ground knitted fabrics 11 and 12, and couples them together. It is composed of a three-dimensional three-dimensional structure having a large number of connecting yarns 13.
[0010]
For example, as shown in FIG. 2, one ground knitted fabric 11 is formed by a flat knitted fabric structure (fine mesh) that is continuous in both the wale direction and the course direction from a yarn in which a single fiber is twisted. Has been. On the other hand, the other ground knitted fabric 12 is, for example, as shown in FIG. 3, more than one ground knitted fabric 11 having a honeycomb-shaped (hexagonal) mesh from a yarn twisted with short fibers. It has a large stitch structure. Of course, this knitted fabric structure is merely an example, and a knitted fabric structure other than a fine structure or a honeycomb shape can be adopted, and a combination thereof is also arbitrary such as adopting a fine structure for both. The connecting yarn 13 is knitted between the pair of ground knitted fabrics 11 and 12 so that one ground knitted fabric 11 and the other ground knitted fabric 12 maintain a predetermined distance, and is a three-dimensional mesh knit. The given three-dimensional solid knitted fabric 10 is given a predetermined rigidity.
[0011]
The thickness of the ground yarn forming the ground knitted fabrics 11 and 12 is not particularly limited, and can be provided with the waist strength necessary for the three-dimensional knitted fabric and the knitting operation is not difficult. Is selected. Moreover, although monofilament yarn can be used as the ground yarn, it is preferable to use a multifilament yarn or a spun yarn from the viewpoint of texture and softness of the surface feel.
[0012]
For example, when the connecting yarn 13 is used as a cushion material for a vehicle seat, a monofilament yarn is preferably used, and one having a thickness of 167 to 1100 dtex is preferable. This is because the multifilament yarn cannot provide a cushioning property having a good restoring force, and if the thickness is less than the above range, it is difficult to obtain waist strength. That is, by adopting the monofilament yarn in the above-described range as the connecting yarn 13, when the three-dimensional solid knitted fabric 10 is used as a cushioning material for a vehicle seat, for example, the load of the seated person is set to each ground knitted fabric. 11 and 12 can be supported by the deformation of the stitches constituting the joint yarn 13, the tilting and buckling characteristics of the connecting yarn 13, and the restoring force of the adjacent connecting yarns 13 that impart spring characteristics to the buckling properties, that is, the restoring force. Can be supported by a buckling characteristic having a soft spring characteristic, and a soft structure having no stress concentration can be obtained.
[0013]
The material of the ground yarn or the connecting yarn 13 is not particularly limited, and examples thereof include synthetic fibers such as polypropylene, polyester, polyamide, polyacrylonitrile, and rayon, recycled fibers, and natural fibers such as wool, silk, and cotton. It is done. The said raw material may be used independently and these can also be used together arbitrarily. Preferably, thermoplastic polyester resins represented by polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide resins represented by nylon 6, nylon 66, etc., polyolefin resins represented by polyethylene, polypropylene, etc. Or a mixture of two or more of these resins. Polyester resins are suitable because of their excellent recyclability. Further, the shape of the ground yarn or the connecting yarn 13 is not limited, and may be a round cross-section yarn or a modified cross-section yarn.
[0014]
As a method of arranging the connecting yarns 13 (pile structure), the connecting yarns 13 that connect the respective ground knitted fabrics 11 and 12 are shown as viewed from the side, more specifically, for example, as shown in FIG. It is classified into such a kind. (A), (b) is a straight type in which the connecting yarn 13 is knitted almost vertically between the ground knitted fabrics 11, 12, and (a) of which is knitted straight into an 8-shape, b) is a simple straight braid. (C) to (e) are cross types knitted so that the connecting yarns 13 cross in the middle between the ground knitted fabrics 11 and 12, and (c) is crossed in a figure 8 shape. , (D) are knitted into a simple cloth, and (e) is a cloth (double cross) made up of two pieces. In addition, as shown in (c) to (e), when the connecting yarns 13 are crossed and arranged obliquely, the connecting yarn 13 is arranged almost vertically between the ground knitted fabrics 11 and 12. In comparison (see (a) and (b)), a soft spring characteristic with a large compression rate can be imparted while maintaining a sufficient restoring force due to the buckling strength of each connecting yarn 13.
[0015]
Next, a method for processing the terminal portion by implanting a fine pile yarn 20 into the above-described three-dimensional solid knitted fabric 10 will be described.
FIG. 5 shows an embodiment when a three-dimensional solid knitted fabric 10 is laminated with a backing 30. First, as shown in FIG. 5A, the three-dimensional solid knitted fabric 10 cut into a predetermined shape is laminated on the lining 30. Next, as shown in FIG. 5 (b), a welding jig is brought into contact with and pressed against the surface of the terminal portion 10 a of the three-dimensional solid knitted fabric 10 and the back surface of the terminal portion 30 a of the lining 30. Preliminary terminal processing is performed to weld both. Thereby, fraying from the cut surface of the three-dimensional solid knitted fabric 10 can be prevented. As the welding means, means such as heat sealing and ultrasonic welding are conceivable. However, the vibration welding means is suitable for reliably performing the welding process on the three-dimensional solid knitted fabric 10 having a predetermined thickness. .
[0016]
Next, as shown in FIG.5 (c), the moquette 25 is laminated | stacked on the surface of the terminal part 10a of the three-dimensional solid knitted fabric 10 in which the lining 30 is not laminated | stacked. As shown in FIG. 6, in the moquette 25, the thin pile yarn 20 is bent into a substantially V shape between the ground yarns 25b, 25c constituting the base fabric 25a, and the bent portion 20a is formed into the base fabric 25a. A large number of free ends 20b located on both sides of the bent portion 20a are woven so as to protrude from the surface of the base fabric 25a. Therefore, when the moquette 25 is laminated so that the back side of the base fabric 25a is bonded to the surface of the three-dimensional solid knitted fabric 10, and the welding means, preferably the vibration welding means for the same reason as described above, the pile yarn 20 is applied. Among them, a bent portion 20 a located on the back side of the base fabric 25 a is welded and fixed to the surface of the terminal portion 10 a of the three-dimensional solid knitted fabric 10. Then, as shown in FIG. 5D, when the base fabric 25a of the moquette 25 is peeled off, the pile yarn 20 welded and fixed to the surface of the terminal portion 10a of the three-dimensional solid knitted fabric 10 has an upper end at the free end 20b. Therefore, the yarn passes through the ground yarns 25b and 25c of the base fabric 25a and is planted on the surface of the terminal portion 10a.
[0017]
At this time, the pile yarn 20 is planted not only from the ground knitted fabrics 11 and 12 positioned at the terminal portion 10a of the three-dimensional solid knitted fabric 10, but also from the surface of the ground knitted fabrics 11 and 12 to the outside. The pile yarn 20 is also planted by welding on the surface of the connecting yarn 13 that protrudes sideways from the cut surface. Therefore, the surfaces of the ground knitted fabrics 11 and 12 and the surface of the connecting yarn 20 have a soft texture, so that the tactile sensation when coming into contact with the human body is improved and the design can be improved. Moreover, since the fine-pile pile yarn 20 is densely planted, it becomes difficult to slip and frictional properties are also improved. Moreover, since the skin material itself is not laminated as in the prior art, but only the pile yarn 20 of the moquette 25, the increase in weight due to flocking is extremely small. In addition, after the pile yarn 20 is welded and fixed to the terminal portion 10a of the three-dimensional solid knitted fabric 10, the raised yarn yarn 20 can be subjected to raising treatment for further improvement in tactile sensation as necessary.
[0018]
Here, the pile yarn 20 before flocking to the three-dimensional solid knitted fabric 10 is already held on the base fabric 25a as a moquette 25 (see FIG. 6). That is, the pile yarn 20 woven into the base fabric 25a as the moquette 25 is transplanted to the three-dimensional solid knitted fabric 10 by welding instead of attaching the thin pile yarn 20 to the three-dimensional solid knitted fabric 10 alone. Is. Accordingly, during the flocking operation on the three-dimensional solid knitted fabric 10, the pile yarn 20 is used for the ground fabric 11, 12 and / or the connecting yarn 13 near the base fabric 25 a of the moquette 25 or the terminal portion 10 a of the three-dimensional solid knitted fabric 10. It is always in a state of being supported by either. For this reason, the pile yarn 20 is present alone and hardly floats during the work, and the worker hardly sucks the floating pile yarn 20. Further, since the pile yarn 20 to be flocked to the three-dimensional solid knitted fabric 10 is transplanted from the moquette 25, as the moquette 25 to be used, a piece cut for use for some purpose, an excess cloth, a defective cloth, or the like is used. This is sufficient for effective use of moquettes and resource saving.
[0019]
In addition, since the bent portion 20a located on the back side of the moquette 25 is welded and pulled out from the base fabric 25a, in consideration of ease of pulling out the pile yarn 20, the mocket 25 has a function of preventing the pile yarn 20 from coming off. The thing of the structure which is not coat | covered with the backing resin which fulfill | performs is preferable. On the other hand, even if the backing resin layer is relatively thin even when it is coated with the backing resin, the resin accelerates welding when the pile yarn 20 is planted on the three-dimensional solid knitted fabric 10. Therefore, it is also preferable to use a material coated with a relatively thin backing resin. In addition, the raw material of the pile yarn 20 is not limited, However, The thermoplastic fiber which can be easily fixed by a welding means is preferable. In addition, the pile yarn 20 is bonded to the three-dimensional solid knitted fabric 10 before the ground yarns 25b and 25c constituting the base fabric 25a start to melt before welding. It is preferable to use finer hairs.
[0020]
FIG. 7 is a diagram illustrating a terminal unit processing method according to another embodiment of the present invention. In the present embodiment, first, as shown in FIG. 7A, a spare portion for crushing the terminal portion 10 a by vibration welding in advance as in the above embodiment on the three-dimensional solid knitted fabric 10 cut into a predetermined shape. The moquette 25 is stacked without performing terminal processing. Next, as shown in FIG. 7 (b), a vibration welding jig is brought into contact with the arbitrary portion to which the pile yarn 20 is to be attached, in this embodiment, the terminal portion 10a, and is welded while being pressed. As a result, of the pile yarn 20, the bent portion 20a located on the back side of the moquette 25 is welded and fixed to the ground knitted fabrics 11 and 12 and / or the connecting yarn 13 located in the vicinity of the terminal portion on the surface of the terminal portion 10a. Is done. Then, as shown in FIG. 7C, when the base fabric 25a of the moquette 25 is peeled off, only the pile yarn 20 that has been welded and fixed is implanted in the terminal portion 10a.
[0021]
FIG. 8 is a diagram illustrating a terminal unit processing method according to still another embodiment of the present invention. This embodiment is different from the embodiment shown in FIG. 7 in that the pile yarn 20 is implanted on both surfaces of the three-dimensional solid knitted fabric 10. That is, in this embodiment, first, as shown in FIG. 8A, the moquettes 25 and 25 are laminated on both surfaces of the three-dimensional solid knitted fabric 10 with the three-dimensional solid knitted fabric 10 interposed therebetween. Next, as shown in FIG. 8 (b), from the outer surface of each of the moquettes 25, 25, a vibration welding jig is brought into contact with and pressed against a portion corresponding to the terminal portion 10a to perform vibration welding. Finally, as shown in FIG. 8C, when the base fabrics 25a and 25a of the respective moquettes 25 and 25 are peeled off, the pile yarns 20 and 20 are welded to both sides of the terminal portion 10a of the three-dimensional solid knitted fabric 10. Remains in a fixed state and is transplanted.
[0022]
As described above, according to the present invention, the three-dimensional three-dimensional knitted fabric 10 can be used in various process steps after a preliminary terminal processing step or without such a preliminary terminal processing step. A fine pile yarn can be planted, and the present invention further includes the following aspects. For example, in each of the above-described embodiments, the pile yarn 20 is implanted in the terminal portion 10a of the three-dimensional three-dimensional knitted fabric 10 so as to improve the tactile sensation and design of the terminal portion. Then, when used as an arbitrary part of the three-dimensional solid knitted fabric 10, for example, as a cushion for a vehicle seat, the pile yarn 20 can be planted in the vicinity of the center, the entire surface, or the like so as to have an arbitrary pattern or character. . That is, a moquette is laminated on a portion where the pile yarn 20 is to be implanted, and a jig for vibration welding is operated so as to be a desired pattern or character, or a shape that becomes the pattern or character is previously set. The pile yarn 20 can be planted in an arbitrary part of the three-dimensional solid knitted fabric 10 by welding the bent part 20a located on the back side of the moquette using the jig having, and peeling off the base fabric in the same manner as described above. it can.
[0023]
Therefore, the design property, tactile sensation, etc. of an arbitrary part (including the entire surface) of the three-dimensional solid knitted fabric 10 can be easily improved by planting the pile yarn 20. Moreover, since the frictional force of the arbitrary part of the three-dimensional three-dimensional knitted fabric 10 can be increased by the frictional force of the piled pile yarn 20, when this is used as a cushion or the like of an automobile seat, the human body holdability And can prevent front slipping when seated. For example, as shown by the cross-hatched line in FIG. 9A, the pile yarn 20 can be laminated on any of the seat cushion portion, the seat back portion, and the headrest portion, and this can be used as a skin. As shown in FIG. 9 (b), a structure in which the pile yarn 20 is laminated only on the side excluding the center portion of the seat cushion portion and the seat back portion may be employed.
[0024]
Here, Fig.10 (a) has shown the one part cross section of the aspect which laminated | stacked the pile thread | yarn 20 on the whole surface of the seat cushion part. As shown in this figure, in the seat cushion part, in order to make it easier to absorb the load of the seated person, when the load is applied and the vicinity of the center of the seat surface sinks, the seat surface is designed so that both sides are brought inward. Usually, a concave line 50 is formed at the boundary between the vicinity of the center and both sides.
[0025]
In such a case, in the structure in which the skin material is laminated on the conventional three-dimensional solid knitted fabric as shown in FIG. 13A, when forming the concave line 150 at the boundary between the center of the seating surface and both sides, Using the three-dimensional three-dimensional knitted fabric 100 for the center of the seat surface and the three-dimensional three-dimensional knitted fabric 110 for the side, and using the two skin materials 120 and 130 in a similar manner, The two outer skin materials 120 and 130 are stacked between the three-dimensional three-dimensional knitted fabrics 100 and 110 and then stitched together by the sewing thread 160 to form a line 150. The conventional cloth-like skin materials 120 and 130 are wrinkled by simply laminating them, and thus it is necessary to sew and apply tension to predetermined portions of the three-dimensional solid knitted fabrics 100 and 110. It is. Accordingly, the three-dimensional three-dimensional knitted fabrics 100 and 110 and the skin materials 120 and 130 overlap each other at the sewing target portion, resulting in a considerable thickness, making it difficult to sew as described above. In addition, in order to apply tension to the skin materials 120 and 130, it was necessary to sew together near the center of the seating surface and each side, so there was a sense of foreign matter near the boundary between the two, and the continuity of rigidity was lost, It was also a factor to reduce the excellent body pressure dispersion characteristic unique to 3D solid knitting.
[0026]
On the other hand, according to the present invention shown in FIG. 10A, it is possible to form the skin by simply planting the pile yarn 20 on the three-dimensional solid knitted fabric 10. Further, even when the concave line 50 is formed by vibration welding in advance so that the three-dimensional solid knitted fabric 10 is in a semi-collapsed state at the boundary between the center of the seat and each side, the pile yarn 20 can be implanted. is there. Therefore, the excellent body pressure dispersion property of the three-dimensional solid knitted fabric 10 can be sufficiently exhibited without breaking the rigidity continuity of the three-dimensional solid knitted fabric 10. In addition, since the concave line 50 is formed by vibration welding, the surface of the concave line 50 is whitened or the color of the connecting yarn comes out. As shown in FIG. By planting hair, this whitened surface can be hidden. Further, when the concave line 50 is pulled downward, it is bent and wrinkles are generated. However, since such wrinkles are also covered by the pile yarn 20, the design of the appearance can be greatly improved. . Moreover, instead of laminating the cloth-like skin material as it is conventionally, it is a configuration in which only the pile yarn 20 can be planted to make the skin, and the weight of the skin formed on the three-dimensional solid knitted fabric is increased. The increase amount can be greatly reduced and the cost can be reduced.
[0027]
According to the present invention, since the pile yarn 20 is fixed to the three-dimensional solid knitted fabric 10 by the welding means, it can be easily welded and fixed to an arbitrary part. Therefore, as shown in FIG. 10A, the type of the pile yarn 20 can be changed depending on the part. For example, as the pile yarn 201 near the center of the seat portion, a dry tactile material can be arranged, and as the side pile yarn 202, a suede-like material with a smooth luster and a slimy feeling can be arranged. . Further, along the concave line 50 formed by vibration welding so as to be in a semi-collapsed state, the pile yarn 203 having long hairs can be planted at a high density so that the line property can be emphasized. .
[0028]
Further, as shown in FIG. 10B, the pile yarn 20 is planted only on the surface of the side and the concave line 50, and in the vicinity of the center of the seat portion, the ground knitted fabric of the three-dimensional solid knitted fabric 10 is directly used as the skin. As such a configuration, depending on the type and application of the sheet to be applied, a configuration that makes use of the feel of the ground knitted fabric can be used. Also in this case, conventionally, as shown in FIG. 13B, it is necessary to sew the skin material 130 covering the side surface between the two three-dimensional solid knitted fabrics 100 and 110, Similar to the above, there was a problem of reduction in body pressure dispersion characteristics due to the presence of foreign matter and lack of rigidity continuity, but such a problem is solved by the configuration shown in FIG. .
[0029]
Furthermore, in the three-dimensional solid knitted fabric 10, the connecting yarn 13 protrudes from the surface of the ground knitted fabrics 11, 12 when the seam of the joint portion between the ground yarn and the connecting yarn 13 constituting the ground knitted fabrics 11, 12 is low. When used as it is, the hard feel of the connecting yarn 13 is transmitted to the human body. On the other hand, as the closing force is increased in order to prevent the connecting yarn 13 from protruding, the surface feel of the three-dimensional solid knitted fabric 10 becomes harder and the spring feel (elasticity) becomes harder. In this respect, according to the present invention, the pile yarn 20 is also planted by the welding means in the joint portion between the ground knitted fabrics 11 and 12 and the coupling yarn 13, and therefore the coupling yarn 13 is formed by the planted pile yarn 20. It is fixed to the ground knitted fabrics 11 and 12, and its protrusion is prevented. For this reason, it is possible to use a material having a soft spring feeling having a lower seam force at the joint portion between the ground knitted fabrics 11 and 12 and the connecting yarn 13 than in the prior art.
[0030]
In the above description, a moquette having a substantially V-shaped pile yarn 20 woven into the base fabric 25a with both ends sandwiched between the bent portions 20a is used. Moquets having a V-shaped portion woven in a continuous state, that is, a pile yarn woven in a substantially W shape, or a pile yarn woven so that a large number of substantially V-shaped portions continue. It is also possible to use a fabric such as The pile yarn has a fine hair shape and is thinner than the ground yarn constituting the base fabric as described above. Therefore, even when the pile yarn is made of the same material, the pile yarn is more easily melted than the ground yarn. Therefore, even a pile yarn woven so as to have a large number of substantially W-shaped or substantially V-shaped portions is continuous before the ground yarn melts due to heat during vibration welding. When the base fabric is peeled off, it is welded and fixed to the three-dimensional three-dimensional knitted fabric 10 for each substantially V-shaped part, and then transplanted. However, considering the ease of passing between the ground yarns constituting the base fabric and the ease of peeling off the base fabric, a moquet having pile yarns with both ends being free ends is preferable. In this case, a material that is not coated with a backing resin, or that is coated relatively thinly, and that can be used to promote welding when the pile resin is transplanted is used. It is preferable as described above.
[0031]
Here, FIG. 11 (a) shows that the amount of protrusion of the base fabric 25'a to the surface side between the ground yarns 25'b of the base fabric 25'a is short at the center 20'b and near both ends 20'b. In a, a moquette 25 ′ having pile yarns 20 ′ woven in a substantially W shape that is long is schematically shown. When such moquette 25 'is laminated and welded, as shown in FIG. 11 (b), in the pile yarn 20' that has been welded and fixed, the vicinity of the center 20'b having short hairs is the welding site. As the angle is near, the rise angle becomes loose. As a result, between the raised ends 20′a and 20′a, the center vicinity 20′b extends slightly obliquely laterally, and it is possible to give an impression that there is a small amount of flocking in appearance. . On the other hand, the vicinity of the center 20′b covers the surface of the main body of the three-dimensional solid knitted fabric 10 (the surfaces of the ground knitted fabrics 11 and 12) between the raised ends 20′a and 20′a. The internal structure of the original three-dimensional knitted fabric 10 is also hidden by this. Therefore, various variations of the skin design can be easily formed by applying the flocking method of the present invention by changing the weaving method of the pile yarns 20 and 20 'into the base fabrics 25a and 25'a. It can be said that it is possible.
[0032]
In the above description, a moquette is exemplified as a fabric provided with pile yarns, but a thin pile yarn is provided, and like a moquette, a fine pile yarn can be welded to a three-dimensional solid knitted fabric. If so, other pile-woven fabrics such as velvet, towels, benjin, and korten can be used. Further, in the above description, the case where the present invention is applied to a sheet such as a vehicle is taken as an example, but the three-dimensional solid knitted fabric in which the pile yarn of the present invention is implanted can be easily formed in various designs and has a design property. Therefore, it is useful even when used as a material for forming hats, shoes and the like.
[0033]
Furthermore, as a method for flocking of the present invention, means as shown in FIG. 12 (a) can be used. That is, for example, when the three-dimensional solid knitted fabric 10 wound in a roll shape and the moquette 25 similarly wound in a roll shape are prepared and unwound, the moquette 25 is attached to the three-dimensional solid knitted fabric 10. If they are arranged so as to be laminated, and both are laminated, they are pressed by the vibration welding jig 40 and are successively welded by vibration. By adopting such means, the three-dimensional solid knitted fabric 10 and the moquette 25 can be unwound and continuously welded by vibration, and the pile yarn 20 can be planted on the three-dimensional solid knitted fabric 10 continuously. Can continue. In addition, after the pile yarn 20 is vibration welded, the three-dimensional three-dimensional knitted fabric 10 in which the pile yarn 20 is planted can be produced one after another by adopting an apparatus configuration capable of continuously peeling the base fabric 25a. The method shown in this figure is suitable for mass production. Further, as shown in FIG. 12B, a three-dimensional solid knitted fabric 10 that is cut into a predetermined shape is used, and a plurality of three-dimensional solid knitted fabrics 10 are successively placed on a conveyance table (not shown). As a device configuration sent to the three-dimensional solid knitted fabric 10, the mocket 25 wound in a roll shape is stacked while being rewound, and the pile yarn 20 is continuously planted in the same manner as described above. It can also be.
[0034]
【The invention's effect】
According to the three-dimensional solid knitted fabric of the present invention, pile yarn is planted by welding on at least one arbitrary portion or end portion of the ground knitted fabric and / or on the connecting yarn near the portion. Therefore, the designability, tactile sensation, frictional force, and the like can be improved by the implanted pile yarn. In addition, because only thin pile yarn can be planted, the surface design is formed by laminating cloth-like skin material, or compared with the conventional one that processed the terminal part using the cloth-like skin material. Thus, the weight can be reduced without increasing the weight. Moreover, since only pile yarn is planted, the high air permeability peculiar to a three-dimensional solid knitted fabric is not impaired.
[0035]
In addition, according to the method of flocking to the three-dimensional solid knitted fabric and the method of treating the terminal portion of the present invention, the fine pile yarn threaded on the fabric is transplanted to an arbitrary part or terminal portion of the three-dimensional solid knitted fabric by welding. Then, the hair is planted. Therefore, the amount of floating during the flocking operation of the fine-pile pile yarn is greatly suppressed, and it is very easily attached to an arbitrary part or terminal part, thereby improving the design, touch, frictional force, etc. of the three-dimensional solid knitted fabric. be able to. In addition, it is possible to form a skin by planting pile yarn by welding, and because a cloth to be used can be cut off or unnecessary cloth, etc., a conventional cloth-like skin material is laminated and sewn. Compared with the case where it did, surface design, such as a sheet | seat, can be formed at low cost, or a terminal part process can be performed.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a main part of a three-dimensional solid knitted fabric used in the present invention.
FIG. 2 is an enlarged plan view showing a part of one ground knitted fabric.
FIG. 3 is an enlarged plan view showing a part of the other ground knitted fabric.
FIG. 4 is a diagram showing various arrangement patterns of connecting yarns.
FIG. 5 is a process diagram showing a method for processing a terminal portion of a three-dimensional solid knitted fabric according to one embodiment of the present invention.
FIG. 6 is a diagram illustrating an example of a moquette used in the embodiment.
FIG. 7 is a process diagram illustrating a method for processing a terminal portion of a three-dimensional solid knitted fabric according to another embodiment of the present invention.
FIG. 8 is a process diagram showing a method for processing a terminal portion of a three-dimensional solid knitted fabric according to still another embodiment of the present invention.
FIG. 9 is a diagram showing an arrangement part of pile yarns in a sheet using the three-dimensional solid knitted fabric of the present invention.
FIG. 10 is a partial cross-sectional view showing a structure in which a three-dimensional solid knitted fabric in which pile yarns are arranged is applied to a cushion material of a seat.
FIG. 11 is a diagram for explaining a method of flocking using a fabric having a substantially W-shaped pile yarn.
FIG. 12 is a diagram for explaining a flocking method suitable for mass production of a three-dimensional solid knitted fabric.
FIG. 13 is a partial sectional view showing the structure of a conventional seat cushion material in which a skin material is attached to a three-dimensional solid knitted fabric by sewing.
[Explanation of symbols]
10 Three-dimensional solid knitting
10a terminal part
11,12 Ground knitted fabric
13 Connecting thread
20,20 'pile yarn
20a Bending part
25,25 'moquette
25a, 25'a base fabric

Claims (6)

A cushioning material for a seat made of a three-dimensional solid knitted fabric formed by joining a pair of ground knitted fabrics spaced apart from each other with a connecting yarn,
It has a concave line formed so as to be in a semi-collapsed state by vibration welding at the boundary between the center of the seating surface and each side, and pile yarn is planted by welding on the surface of the concave line. Cushion material . A seat, wherein the cushion material according to claim 1 is used in a seat cushion portion . Each other cushion material sheet consisting of three-dimensional net that will be formed by combining spaced pair of ground knitted fabrics each other disposed in the connecting yarn, a method for flocking the pile yarn,
A fabric in which pile yarn is woven between the ground yarns constituting the base fabric is laminated on the surface of the concave line formed so as to be semi-crushed by vibration welding at the boundary between the center of the seat surface and each side. By applying welding means, a part of the pile yarn is welded and fixed to the ground knitted fabric and the connecting yarn in the vicinity of the portion in the concave line , and then the base fabric of the fabric is peeled off to form the concave shape. A pile yarn- implanting method characterized in that the pile yarn welded and fixed to the ground knitted fabric in the line and the connecting yarn in the vicinity of the portion remains to be implanted. In the step of laminating the fabric on the surface of the concave line, the fabric yarn is laminated so that the back side of the pile yarn is not in contact with the protruding side, and in the step of applying the welding means, the pile yarn woven between the ground yarns 4. A method of filing pile yarn according to claim 3, wherein a bent portion located on the back side of the base fabric is welded and fixed to the ground knitted fabric in the concave line and the connecting yarn in the vicinity of the portion . 5. The pile yarn- implanting method according to claim 3, wherein a moquette is used as the fabric . 6. The pile yarn flocking method according to claim 3, wherein vibration welding means is used as the welding means .

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