JP7648064B2 - Knitted garment using natural fiber yarn and manufacturing method for knitted garment using natural fiber yarn - Google Patents

Description

The present invention relates to knitted garments, such as sweaters and cardigans , made using natural fiber yarns .

Circular knit fabrics used in knit products such as girdles, leggings, brassieres, and other complementary innerwear products, as well as sports bottom wear and compression wear such as sports underwear, include those with high and low stretch portions (see, for example, Patent Document 1).

In the circular knitted fabric of Patent Document 1, the ground yarn is the same in the low elongation section and the high elongation section, the low elongation section contains heat-sealed yarn, and at least some of the heat-sealed yarns are heat-sealed to each other. Elastic yarns such as polyurethane and polyether ester are used as the ground yarn in the circular knitted fabric of Patent Document 1. The heat-sealed yarn in the circular knitted fabric of Patent Document 1 is a fiber that has the property of melting and fusing by heat treatment at 120°C for 1 minute in dry heat or 110°C for 30 seconds in wet heat, and polyamide-based fibers, polyester-based fibers, polyurethane-based fibers, etc. are used.

Patent No. 5688240

Knitted fabrics have loops that are connected continuously, so compared to woven fabrics, they have the advantages of being highly elastic and flexible, as well as having excellent heat retention.

However, knitted clothing made from natural and/or synthetic fiber yarns has drawbacks, such as being prone to losing its shape (e.g., stretching due to gravity when hung on a hanger) and shrinking after washing, etc.

In particular, in the case of knitted clothing made with natural fiber yarn, when washed in water, the hydrophilic fibers absorb moisture and become thicker and shorter, and may shrink by as much as 10%, for example.

Furthermore, when the natural fiber yarn is wool, there is a disadvantage that when a knitted garment using the natural fiber yarn is washed in water, the fibers become entangled and shrink (felt) when force is applied thereto, such as by kneading, rubbing, or pushing, while the garment is wet.

In knitted garments such as sweaters and cardigans using natural fiber yarns, when using the heat-sealing yarn in the circular knit fabric of Patent Document 1 to suppress the expansion and contraction of the ground yarn, it is necessary to carry out a heat treatment with dry heat at 120° C. for 1 minute or with wet heat at 110° C. for 30 seconds in order to fuse the heat-sealing yarn to the ground yarn. When carrying out a heat treatment with dry heat at 120° C. for 1 minute or with wet heat at 110° C. for 30 seconds, depending on the natural fiber yarn used in the knitted garment, the fibers may be damaged, resulting in a loss of texture.

Furthermore, to perform a dry heat treatment at 120°C for 1 minute or a wet heat treatment at 110°C for 30 seconds, it is necessary to use a large-scale heat treatment device such as a pin tenter dry heat setting machine or an autoclave wet heat setting machine after knitting the knitted fabric containing the heat-sealing yarn. This requires a necessary capital investment and makes small-lot production difficult. If a factory that owns such a large-scale heat treatment device is requested to perform the heat treatment of the knitted fabric containing the heat-sealing yarn, the production period will be longer.

The present invention aims to effectively suppress the stretching of ground yarns in knitted clothing made of natural fiber yarns without impairing the texture and without using a large-scale heat treatment device.

The knitted garment using natural fiber yarn according to the first aspect of the present invention comprises a ground yarn using natural fiber yarn, and a non-elastic heat-fusible yarn having a fineness of 30 denier or more and 150 denier or less, which melts at 105°C or less, knitted into the ground yarn, with the heat-fusible yarn fused to all or a part of the ground yarn , and the garment is produced on a flat knitting machine .

A knitted garment using natural fiber yarn according to a second aspect of the present invention is a knitted garment using natural fiber yarn according to the first aspect, in which the heat-sealing yarn is a nylon heat-sealing yarn having a melting point of 75°C or higher and 90°C or lower.

A manufacturing method for a knitted garment using natural fiber yarn according to a third aspect of the present invention includes a first step of manufacturing a knitted garment using a flat knitting machine while knitting a non-elastic heat-fusible yarn, which has a fineness of 30 denier or more and 150 denier or less and melts at 105°C or less, into all or a part of a ground yarn using natural fiber yarn, and the knitted garment in a state in which the heat-fusible yarn is not melted, and a second step of melting the heat-fusible yarn with a steam iron for the knitted garment that has undergone the first step, thereby fusing the heat-fusible yarn to the ground yarn.

A fourth aspect of the present invention relates to a method for manufacturing a knitted garment using natural fiber yarn, which is the method for manufacturing a knitted garment using natural fiber yarn according to the third aspect, in which the heat-sealing yarn is a nylon heat-sealing yarn having a melting point of 75°C or higher and 90°C or lower.

The knitted garment using the natural fiber yarn according to the present invention and the knitted garment manufactured by the manufacturing method of the knitted garment using the natural fiber yarn according to the present invention use the natural fiber yarn as the ground yarn. Since the heat-fusible yarn, which is not an elastic yarn and has a fineness of 30 denier or more and 150 denier or less, is fused to all or a part of the ground yarn using the natural fiber yarn, the stretching of the ground yarn using the natural fiber yarn can be suppressed.

By weaving the heat-sealed yarn into all or part of a ground yarn made of natural fiber yarn, and manufacturing a knit garment using natural fiber yarn in which the heat-sealed yarn is not melted by shaping knitting using a flat knitting machine , it is possible to efficiently manufacture knit garments using natural fiber yarn in which the heat-sealed yarn is not melted while reducing the amount of yarn used and cutting loss.

Since the heat-sealed yarn melts at 105° C. or less, the heat-sealed yarn can be melted and fused to the ground yarn by an efficient operation using a steam iron , which is moved so as to apply steam to the required places where the heat-sealed yarn is present on the knitted garment using natural fiber yarn, without using a complex heat treatment device. Therefore, the texture of the knitted garment using natural fiber yarn is not damaged, and small-lot short-cycle production that meets the individualization and diversification of consumer needs is possible.

This is a knitting diagram of Milanese rib knitting. This is a knitting diagram for single rib knitting.

<Knitted clothing made from natural fiber yarn >
The knitted garment using natural fiber yarn of the present invention uses natural fiber yarn as the ground yarn . That is, the knitted garment uses only natural fiber yarn , or uses a blended yarn in which natural fiber and synthetic fiber are mixed at a predetermined mixing ratio. The fineness of the yarn is 1 to 100. For example, cotton yarn, wool yarn, animal wool yarn, etc. are used as the natural fiber yarn. For example, acrylic, polyester, etc. are used as the synthetic fiber yarn.

The knitted garments using the natural fiber yarn of the present invention are knitted garments made on a flat knitting machine, and include, for example, sweaters, cardigans, dresses, skirts, and the like.

There is no limitation on the type of knitting method for knitted clothing using the natural fiber yarn of the present invention. That is, the knitting method for knitted clothing using the natural fiber yarn of the present invention may be any knitting method that allows weft knitting, such as plain knit, rib knit, Milanese rib knit, rib knit, pique knit, garter stitch (pearl knit), openwork knit, etc.

In the knitted garment using the natural fiber yarn of the present invention, a non-elastic heat-fusible yarn that melts at 105° C. or less is fused to all or a part of the ground yarn using the natural fiber yarn. The heat-fusible yarn melts at 105° C. or less, and is, for example, a nylon heat-fusible yarn with a melting point of 75° C. to 90° C.

The fineness of the heat-sealing yarn is between 30 and 150 denier, and is selected to achieve the desired texture depending on the thickness and hardness of the knitted fabric.

In the knitted garment using the natural fiber yarn of the present invention, the thermal fusion yarn is fused to all or a part of the ground yarn using the natural fiber yarn, so that the expansion and contraction of the ground yarn can be suppressed. By knitting the natural fibers of the ground yarn and the thermal fusion yarn in a required ratio, the shrinkage of the natural fiber can be controlled.

<Manufacturing method for knitted clothing using natural fiber yarn>
The knitted garment using the natural fiber yarn of the present invention is manufactured by a flat knitting machine that creates a shape according to a pattern. That is, a heat-sealing yarn that melts at 105°C or less and is not an elastic yarn is knitted into all or a part of a ground yarn using the natural fiber yarn, and a knitted garment using the natural fiber yarn in a state where the heat-sealing yarn is not melted is manufactured by the flat knitting machine (first step). For example, by manufacturing a knitted garment using the natural fiber yarn by shaping knitting using the flat knitting machine, it is possible to efficiently manufacture a knitted garment using the natural fiber yarn in a state where the heat-sealing yarn is not melted while reducing the amount of yarn used and cutting loss.

Next, the heat-sealed yarn is melted by a steam iron that sprays high-temperature steam from holes on the bottom of the knitted garment using the natural fiber yarn , and the heat-sealed yarn is fused to the ground yarn (step 2). Since the heat-sealed yarn melts at 105°C or less, the heat-sealed yarn can be melted and fused to the ground yarn by an efficient operation using a steam iron , for example, by moving an electric steam iron of 1000W to 1500W so as to apply steam to the required places where the heat-sealed yarn is present on the knitted garment using the natural fiber yarn, without using a large-scale heat treatment device.

<Examples of non-elastic heat-fusible yarns that melt at 105°C or less>
In a preferred embodiment, a nylon heat-sealing yarn having a melting point of 75° C. or higher and 90° C. or lower is used as the heat-sealing yarn that is not an elastic yarn and melts at 105° C. or lower.

As examples of nylon heat-sealed yarn with a melting point of 75°C or higher and 90°C or lower, for example, "Nylon heat-sealed yarn" (melting point 80°C) from CHANGZHOU CITY LINGXIAN TEXTILE EQUIPMENT CO., LTD., or "Japanese-made heat-sealed yarn 78T" (melting point 85°C) from Mitsubishi Chemical Corporation can be used.

<Example of how to insert heat-sealing thread>
(1) To suppress longitudinal and lateral stretch In plain knitting, rib knitting, rib knitting, etc., a ground yarn and a heat-sealed yarn are inserted throughout the entire knitting. Double mill knitting, in which two different yarns are pulled in at the same time, is preferable. The ground yarn and the heat-sealed yarn pass through separate yarn insertion ports toward the head of the flat knitting machine, where they join together.

(2) When preventing horizontal stretch while maintaining vertical stretch For example, in the knitting diagram of Milanese rib knitting shown in Figure 1, (1) the ground yarn that loops with the latch needle on the front needle bed and the latch needle on the back needle bed (rib knit ground yarn), (2) the ground yarn that loops only with the latch needle on the back needle bed, and (3) the ground yarn that loops only with the latch needle on the front needle bed, a heat fused yarn is aligned with the ground yarns of (2) and (3) (the heat fused yarn is knitted in).

For example, in the knitting diagram of one-rib knitting shown in Figure 2, among the ground yarns of the tuck knitting (1) and the rib knitting (2), the heat-sealed yarn is aligned with the ground yarn of (1) (the heat-sealed yarn is knitted in).

(3) When the knitted fabric needs to be stretched while maintaining its shape stability, for example, in the Milanese rib knitting diagram shown in Figure 1, a heat-sealed yarn is aligned with the rib knit ground yarn of (1) (the heat-sealed yarn is knitted in).

For example, in the knitting diagram of the single rib knit shown in Figure 2, the heat-sealed yarn is aligned with the ground yarn of the rib knit (2) (the heat-sealed yarn is knitted in).

<Specific method for adjusting tension of knitted garments using natural fiber yarn >
The tension (range of stretch) of a knitted garment made using natural fiber yarn can be adjusted, for example, as follows, by the way in which heat-sealing yarn is inserted into the ground yarn of the course, which is a row of loops arranged horizontally in the knitted fabric.

(1) When the tension is very low, the ground yarn of all courses is knitted together with the heat-sealing yarn.

(2) When the tension is reduced, three courses are knitted with the ground yarn together with the heat-sealing yarn, and two courses are knitted with only the ground yarn, and this process is repeated.

(3) When the tension is normal, one course is knitted with the ground yarn together with the heat-sealing yarn, and one course is knitted with only the ground yarn, and this process is repeated.

(4) When the tension is increased, two courses are knitted together with the ground yarn and the heat-sealing yarn, and then three courses are knitted using only the ground yarn, and this process is repeated.

(5) When the tension is very high, one course is knitted with the ground yarn together with the heat-sealing yarn, and then nine courses are knitted with only the ground yarn, and this is repeated.

<Evaluation of Washing Resistance>
(Evaluation Method)
Based on the C4M method of JIS L 1930:2014 "Home washing test method for textile products" (washing for 6 minutes at 40°C, rinsing for 2 minutes twice, spin-drying for 3 minutes each, and drying by hanging), the dimensional change rate after washing and drying is calculated as [(length after treatment) - (length before treatment)] / (length before treatment).

(Subject to evaluation)
The evaluation subject is a sweater made of Milanese rib knitted natural fiber yarn (ground yarn is 100% cotton with a count of 2/100).

Examples and Comparative Examples
The sweater was produced on a flat knitting machine using 50 denier "Japanese heat fusion yarn 78T" (melting point 85°C) manufactured by Mitsubishi Chemical Corporation as the ground yarn for the rib knit (1×1 rib) of (1) in the knitting diagram of Milanese rib knitting shown in Figure 1, and the heat fusion yarn was melted and fused to the ground yarn with a steam iron to form the Example. The sweater without the heat fusion yarn is the Comparative Example.

(Evaluation Results)
The dimensional change rates for the body length, body width, sleeve length, and hem width were calculated after one washing and drying cycle in the washing test method of the evaluation method, and after five cycles of washing and drying, and are shown in Table 1. Positive values indicate "stretch" and negative values indicate "shrinkage."

After one wash and dry of the comparative sweater using the natural fiber yarn , the length, width and sleeve length are shrunk, and the hem width is stretched. After five wash and dry of the comparative sweater, the length and width are shrunk, and the sleeve length and hem width are stretched. After five wash and dry of the comparative sweater, the length has shrunk by 6.3%, which is large.

In contrast, the sweater using the natural fiber yarn of the embodiment shrank in length, width, sleeve length and hem width both after one wash and dry and after five wash and dry cycles.

After washing and drying the sweater of the embodiment once , the greatest shrinkage is in the length, which is 1.7%. This shrinkage (1.7%) is about 57% smaller than the shrinkage (3.0%) of the sweater of the comparative example after washing and drying once . After washing and drying the sweater of the embodiment five times, the greatest shrinkage is in the length, which is 3.7%. This shrinkage (3.7%) is about 59% smaller than the shrinkage (6.3%) of the sweater of the comparative example after washing and drying five times.

As described above, it can be seen that the sweater made using the natural fiber yarn of the Example has much higher shape stability after repeated washing and drying and has a significantly smaller maximum shrinkage amount than the sweater made using the natural fiber yarn of the Comparative Example.

<Action and effect>
The knitted garment using natural fiber yarn according to the embodiment of the present invention as described above uses natural fiber yarn as the ground yarn. Since the heat-sealing yarn is fused to all or a part of the ground yarn using the natural fiber yarn, the stretching of the ground yarn can be suppressed.

By weaving the heat-sealed yarn into all or part of the ground yarn and producing a knitted garment using natural fiber yarn in which the heat-sealed yarn is not melted, for example by shaped knitting using a flat knitting machine, it is possible to efficiently produce knitted garments using natural fiber yarn in which the heat-sealed yarn is not melted while reducing the amount of yarn used and cutting loss.

Since the heat-sealed yarn melts at 105° C. or less, the heat-sealed yarn can be melted and fused to the ground yarn by an efficient operation using a steam iron , which is moved so as to apply steam to the required places where the heat-sealed yarn is present on the knitted garment using natural fiber yarn, without using a complex heat treatment device. Therefore, the texture of the knitted garment using natural fiber yarn is not damaged, and small-lot short-cycle production that meets the individualization and diversification of consumer needs is possible.

The above description of the embodiments is merely illustrative and is not intended to be limiting. Various improvements and modifications may be made without departing from the scope of the present invention.

Claims (4)

The ground thread is made of natural fiber yarn,
a heat-fusible yarn that is not an elastic yarn and has a fineness of 30 denier or more and 150 denier or less and melts at 105°C or less, which is woven into the ground yarn;
It consists of:
The heat-fusible yarn is fused to all or a part of the ground yarn ,
It was made on a flat knitting machine .
Knitted clothing made from natural fiber yarn. The heat-sealing yarn is a nylon heat-sealing yarn having a melting point of 75° C. or more and 90° C. or less.
A knitted garment made using the natural fiber yarn according to claim 1. A first step of knitting a non-elastic heat-fusible yarn having a fineness of 30 denier or more and 150 denier or less, which melts at 105°C or less, into all or a part of a ground yarn using natural fiber yarn, while manufacturing a knit garment in a state in which the heat-fusible yarn is not melted, using a flat knitting machine;
A second step of melting the heat-sealing yarn with a steam iron on the knitted garment that has been subjected to the first step, thereby fusing the heat-sealing yarn to the ground yarn;
Including,
A method for manufacturing knitted garments using natural fiber yarns. The heat-sealing yarn is a nylon heat-sealing yarn having a melting point of 75° C. or more and 90° C. or less.
A method for producing knitted garments using the natural fiber yarn according to claim 3 .

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