JP4431906B2 - Stretch knitted fabric for interior, manufacturing method thereof and sheet forming method - Google Patents

Description

【００３０】
【表２】

【００３１】
【表３】

【００３２】
【発明の効果】
本発明によると、近年環境汚染等で問題視されている従来型のウレタンクッション材を使用せずとも良好なクッション性能と着座感が得られ、個人の嗜好に合う意匠性の付与されたリサイクル可能な椅子張り用若しくは車両用伸縮性編地、その製造方法及びシート成形方法を提供することを可能とした。
【図面の簡単な説明】
【図１】本発明の編組織図の一例。
【図２】本発明の糸入れ配置図の一例。
【図３】比較例２の編組織図。
【図４】比較例２の糸入れ配置図。
【符号の説明】
Ｌ１：第１筬、Ｌ２：第２筬。[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a stretch knitted fabric for interior, a method for producing the same, and a sheet forming method, and specifically, for a chair upholstery having good cushioning performance and seating feeling and designability without having a cushioning material such as urethane. Or, it relates to a stretchable knitted fabric sheet for vehicles.
[0002]
[Prior art]
Currently, urethane foam, polyester fiber-filled cotton, resin cotton bonded with polyester fiber, solid cotton, and the like are used as cushion materials for seats for chairs and vehicle seats. However, urethane foam has problems because it is difficult to handle chemicals used during production, discharges chlorofluorocarbons, and is difficult to recycle. Polyester foam stuffed cotton, resin cotton bonded with polyester fiber, As for cotton and the like, there is a problem that the cushioning property is lowered due to the sag on the fiber structure over time.
[0003]
Recently, fabrics using polyester elastic yarns and polyester processed yarns have been put on the market in order to solve these problems. However, these woven fabrics have a large proportion of the polyester elastic yarn that directly contacts the human body due to the structure of the woven fabric, and are very hard, and are not capable of withstanding long-term use, and have considerable limitations in terms of design.
[0004]
[Problems to be solved by the invention]
The present invention solves the problems of the conventional seats for chairs and vehicle seats, provides good cushioning performance without using cushioning materials, soft seating feeling that can withstand long-term use, and individual preference. The present invention relates to the provision of a stretchable knitted fabric for interior to which a suitable design property is imparted, a manufacturing method thereof, and a sheet forming method.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, the present invention requires the following configuration. That is, the invention according to the present invention is a polyether ester having a breaking elongation (DE) of 50 to 200%, a total denier of 200 to 6000 denier, and a 160 ° C. dry heat shrinkage (SHD) of 12 to 60%. A knitted fabric in which a polyester-based fiber yarn having a total denier of 100 to 3000 denier is arranged on the front heel, and a 10% elongation of the knitted fabric has an elongation stress of 30 kgf / 5 cm or less. A stretch knitted fabric for interiors having a breaking strength in both directions of 50 kgf / 5 cm or more, preferably the polyetherester elastic yarn is a core-sheath type composite elastic yarn The stretchable knitted fabric for interior according to the above, wherein the polyetherester elastic yarn is fused to the adjacent yarn, A stretch knitted fabric for interiors as described above, wherein a flame retardant and / or a light resistance agent is applied to the ether ester elastic yarn, and the polyether ester elastic yarn has a 160 ° C. dry heat shrinkage (SHD) of polyester The stretchable knitted fabric for interior according to the above, characterized in that it is 5 to 50% higher than the 160 ° C. dry heat shrinkage (SHD) of the system fiber yarn.
[0006]
The invention according to the production method of the present invention is characterized by knitting by placing a polyether ester elastic yarn on the back side of a warp knitting machine comprising two or more warps and a polyester fiber yarn on the front side. A stretchable knitted fabric for interiors according to the above, characterized in that the yarn is knitted by knitting with dyed yarns made of polyester-processed yarn on at least two front wings. A method for producing a stretch knitted fabric for interior according to the above, wherein a part or all of the polyether ester elastic yarn is inserted with a single stitch structure, and a polyether ester elastic The method for producing a stretch knitted fabric for interior as described above, wherein the core-sheath type composite elastic yarn and the single component elastic yarn are alternately knitted as the yarn, and the polyether ester type after knitting Core-sheath type compound bullet Yarn sheath side above the melting point, a method for interiors for stretchable knitted fabric prepared above, wherein the heat treatment at a temperature lower than the core side melting point.
[0007]
Further, the invention according to the molding method of the present invention is characterized in that the above-mentioned knitted fabric is tension-fixed on all sides to a frame and then set by applying heat less than the melting point of the polyetherester elastic yarn. This is a sheet forming method for a knitted fabric.
The present invention is described in detail below.
[0008]
The polyether ester-based elastic yarn used in the present invention is a yarn comprising a block ether ester-based elastic body having an aromatic polyester, which uses aromatic dicarboxylic acid and glycol as main raw materials, as a hard segment and polyalkylene glycol as a soft segment. It is preferable that In particular, a terephthalic acid polyester composed of terephthalic acid and ethylene glycol or terephthalic acid and butanediol is used as a hard segment, and a polyether such as polyethylene glycol or polytetramethylene glycol is used as a soft segment. Furthermore, a polyetherester elastic yarn obtained by copolymerizing polybutylene terephthalate and polytetramethylene glycol has a good elongation recovery and is more preferable.
[0009]
The polyether ester elastic yarn thus obtained has a breaking elongation (DE) of 50% to 200%, a total denier of 200 to 6000 denier, and a 160 ° C. dry heat shrinkage (SHD) of 12% to 60%. The following is desirable. When the elongation at break is less than 50%, the seating feeling is hard, and when it exceeds 200%, the stretch recovery is weak, which is not preferable. Further, when the total denier is less than 200 denier, the production efficiency of the knitted fabric is poor, and conversely, when the total denier exceeds 6000 denier, the thickness cannot be handled by a general-purpose knitting machine. In addition, when the 160 ° C. dry heat shrinkage (SHD) is less than 12%, it is difficult to loosen during molding. Conversely, when it exceeds 60%, the balance with the polyester yarn controlling the design property is lost, and the physical properties of the fabric deteriorate. It is not preferable.
[0010]
The polyetherester elastic yarn is knitted together with a polyester fiber yarn having a total denier of 100 denier or more and 3000 denier or less.
The polyester fiber yarn used here is a polyethylene terephthalate multifilament yarn or a multifilament yarn obtained by copolymerizing polyethylene terephthalate with 5-sodium sulfonic acid metal salt or isophthalic acid as a main component. It is a yarn made of multifilament yarn containing an inert substance.
If this is less than 100 denier, the production efficiency is poor. Conversely, if it exceeds 3000 denier, it cannot be handled by a general-purpose knitting machine. Polyester fiber yarns are generally subjected to various yarn processing such as false twisting and taslan processing in order to improve the handleability, and either white yarn or pre-dyed yarn may be used. As described above, polyester fiber yarns are properly used depending on the purpose of design, but it is needless to say that the purpose of use is to improve the seating feeling, the design, and the product quality.
[0011]
The knitted fabric thus obtained preferably has a 10% weft elongation stress of 30 kgf / 5 cm or less and a breaking strength in both the weft directions of 50 kgf / 5 cm or more. When the stress at the time of 10% elongation exceeds 30 kgf / 5 cm, the seating feeling is hard and unfavorable. On the contrary, even when the stress at the time of 10% elongation is extremely low, the sinking amount is large and a good seating posture cannot be maintained. . Therefore, it is desirable that the stress in each direction at the time of 10% elongation is in the range of 3 to 20 kgf / 5 cm. Further, if the breaking strength in both directions is less than 50 kgf / 5 cm, it is not preferable because a problem of fabric breakage due to insufficient strength is likely to occur. Therefore, the higher the breaking strength, the better from the viewpoint of durability, but at the same time the cost increases. Therefore, it is desirable to design appropriately according to the purpose of use.
[0012]
In addition, the polyetherester elastic yarn is a core-sheath type composite elastic yarn, the polyetherester elastic yarn is fused with the adjacent yarn, the polyetherester elastic yarn is flame retardant and / or light resistant. It is desirable that the agent is applied, and that the 160 ° C. dry heat shrinkage of the polyetherester elastic yarn is 5 to 50% higher than the dry heat shrinkage of the polyester fiber yarn. Polyether ester-based elastic elastic yarn is a core-sheath type composite elastic yarn. When it is fused with an adjacent yarn, the knitted fabric form is stable, and when a flame retardant and / or a light-proofing agent are added, the quality is improved. Since both can be improved, both are preferable directions.
[0013]
The larger the melting point difference of the polyetherester-based core-sheath type elastic yarn, the better the handleability at the time of thermal bonding, but due to the problem of spinnability, the melting point difference is 60 to 20 ° C, preferably 50 to 30 ° C. Thus, it is preferable to increase the melting point on the core side. The melting point of the polyether ester elastic yarn constituting the polyether ester single component elastic yarn is 150 to 200 ° C., and in the case of the core-sheath type composite elastic yarn, the melting point of the core component is 150 to 200 ° C. The melting point is designed to be 60 to 20 ° C. lower than that. The core sheath has a core cross-sectional area ratio of 50% or more, preferably 70 to 95%, and the heat fusion treatment is preferably performed at a temperature 10 to 40 ° C. higher than the melting point on the sheath side. .
[0014]
Further, as a flame retardant, a method of adding melamine cyanurate or using a phosphorus copolymer is known, but the method is not limited to this, and the addition amount is 100 parts by weight of a polyether ester elastic yarn constituent. The range of 1 to 30 parts by weight is preferred. Further, the light-resistant agent is also known to be formulated by adding carbon black or the like, but is not limited thereto, and the addition amount is 0.1 to 5 parts by weight with respect to 100 parts by weight of the polyetherester-based elastic yarn component. The range of is preferable. In addition, it is preferable for the 160 ° C. dry heat shrinkage to be 5 to 50% higher than the dry heat shrinkage of the polyester fiber yarn, since the subsequent moldability can be improved.
[0015]
In addition, these knitted fabrics are knitted using a polyester-based elastic yarn on the back side of a warp knitting machine comprising two or more pieces of polyester ester-based elastic yarn, and polyester fiber yarns on the front side, preferably warp knitting. It is preferable that a dyed yarn made of polyester-processed yarn is used for at least two front ridges of the machine, and the design is given. This makes it possible to improve the soft seating feeling that can withstand long-term use and to provide a design that suits each person's preference.
[0016]
A part or all of the polyether ester elastic yarn is inserted in a single-swing structure, and the polyether ester core-sheath composite elastic yarn and the polyether ester single component elastic yarn are alternately arranged. Knitting, and heat-bonding the adjacent yarns by heat treatment at a temperature above the melting point of the sheath side of the polyetherester core-sheath type composite elastic yarn after knitting and below the melting point of the core side, etc. It is desirable to employ the manufacturing method because the knitted fabric form is more stable and the quality is improved.
[0017]
It is preferable that a part or all of the polyether ester elastic yarn is inserted in a single-waving structure because the elastic yarn's stretch properties are easily reflected directly on the fabric properties and the recoverability is improved. Further, in some cases, it is more preferable to insert a relatively fine denier polyetherester elastic yarn with a swing width of 2 stitches or more into the back heel to obtain a fabric having a planar stretch recovery characteristic. In addition, the polyetherester core-sheath type composite elastic yarn and the polyetherester single component elastic yarn are alternately arranged and knitted, so that the sealing effect is not too strong and the cushioning property is good. Become. The composition ratio is preferably an alternating arrangement, but the same effect can be obtained if it is in the range of 3: 1 to 1: 3.
[0018]
These are cushions having a stable form by a manufacturing method in which heat treatment is performed at a temperature not lower than the melting point of the sheath side of the polyetherester core-sheath type composite elastic yarn after knitting but lower than the melting point of the core side, and the adjacent yarns are thermally bonded. A fabric with good properties can be obtained.
The heat treatment is preferably performed at a temperature 10 to 40 ° C. higher than the melting point of the sheath.
[0019]
Further, if the method of setting the knitted fabric to the frame in tension on all sides and then applying the heat below the melting point of the polyetherester elastic yarn is set, the working efficiency can be greatly improved.
The knitted fabric mentioned here is preferably a warp knitted fabric produced by using a warp knitting machine such as a tricot or a Russell machine, but is not limited thereto.
Further, it is desirable that the stretch recovery characteristics of the fabric according to the present invention is a product that recovers 90% or more, more preferably 95% or more after elapse of 24 hours, when 10% stretches.
[0020]
【Example】
Hereinafter, the present invention will be described in detail by way of examples. In addition, the physical property in this invention and evaluation were calculated | required with the following method.
[0021]
1. The tensile strength of the fabric was measured using a Tensilon tensile tester manufactured by Orientec Co., Ltd., with a sample length of 200 mm, a test piece width of 50 mm, and a tensile speed of 100 mm / min. And the strong elongation at the time of a fracture | rupture and the stress at the time of 10% elongation were calculated | required from the obtained chart. Further, a new sample marked with a fixed point was set, applied with a stress at the time of 10% elongation read from the chart, and then allowed to stand at room temperature, and the elongation recovery characteristics after 24 hours were evaluated.
[0022]
2. Measurement of sinking amount (deflection) After fixing the sample in a 40cm square steel frame without slack at room temperature, heat treatment was performed in a hot air dryer at 170 ° C for 1 minute. Then, after positioning so that the center of a frame center part and the disk-shaped compression jig | tool with a radius of 10 cm fixed to the load cell may correspond, the stress of 45 kgf was applied and the amount of sinking at that time was measured. A good sinking amount is in a range of 20 to 60 mm.
[0023]
3. Melting | fusing point measurement The melt | dissolution peak temperature was measured with the nitrogen flow rate of 40 cc / min and the temperature increase rate of 20 degree-C / min using the SSC5200 type | mold differential scanning calorimeter by Seiko Denshi Kogyo.
[0024]
Example 1
Using a 9G Russell machine (RM-6F) made of KARL MAYER, and using the polyester yarns listed in Table-2 on the three foreheads, the design is improved and the seating feeling is improved. Two elastic yarns listed in Table-1 were used to produce a knitted fabric aimed at imparting a function of elongation recovery, and the amount of sinking was evaluated by the method described in the text. In addition, in order to improve the stretch recovery performance, the L4's rear heel has two 2000 denier elastic yarns aligned and inserted with a swing width between one stitch, and in order to provide a weft stretch recovery function, A structure was created in which a relatively fine denier elastic yarn was swung between four needles at the back end. (Refer to FIG. 1 and FIG. 2) The obtained knitted fabric had a good appearance and a feeling of sitting as an interior seat. In the evaluation of recovery characteristics, a product recovering 90% or more in 24 hours after 10% elongation was considered good, and the sitting feeling was evaluated by sensory evaluation of the subject. (See Table 3)
[0025]
(Example 2)
In the same way, using a 9G Russell machine (RM-6F) made of KARL MAYER, and using the polyester yarns listed in Table-2 on the front 3 sheets, while improving the design and the feeling of sitting After producing a knitted fabric aiming at providing a function of stretch recovery using the elastic yarns shown in Table-1 on the two back heels, the amount of sinking and the like were evaluated by the method described in the text. In order to improve the stretch recovery performance, as in Example 1, two 2000-denier elastic yarns are inserted into the rear end of L4 with a swing width between one stitch, giving a weft stretch recovery function. In order to do this, a structure in which a relatively fine denier elastic yarn was swung between four needles at the back of L5 was assembled. (See Figs. 1 and 2)
The obtained knitted fabric was tension-fixed on four sides to a metal frame and subjected to heat treatment at 170 ° C. for 1 minute. The obtained sheet had a stable fabric form and had a good appearance and seating feeling as an interior seat. (See Table 3)
[0026]
(Example 3)
Similarly, using a 12G Russell machine (RM-6F) made of 5 pieces of KARL MAYER, and using the polyester yarns listed in Table-2 on the front 3 sheets, while improving the expression of design and the feeling of sitting After producing a knitted fabric aiming at providing a function of stretch recovery using the elastic yarns shown in Table-1 on the two back heels, the amount of sinking and the like were evaluated by the method described in the text. In order to improve the stretch recovery performance, as in Example 1, two 2000-denier elastic yarns are inserted into the rear end of L4 with a swing width between one stitch, giving a weft stretch recovery function. In order to do this, a structure in which a relatively fine denier elastic yarn was swung between four needles at the back of L5 was assembled. (See Figs. 1 and 2)
The obtained knitted fabric was tension-fixed on four sides to a metal frame and subjected to heat treatment at 170 ° C. for 1 minute. Since the core-sheath type composite elastic yarn was inserted over the entire surface, the obtained sheet had a stable fabric form without misalignment, and had a good appearance and seating feeling as an interior seat sheet. (See Table 3)
[0027]
(Comparative Example 1)
Also using a 9G Russell machine (RM-6F) made of 5 pieces of KARL MAYER, using the same polyester yarn as the example on the front fore, and elastic yarns listed in Table 2 on the back fore Polyester yarn having an equivalent denier was knitted with the same structure as in the examples, and the amount of sinking was evaluated by the method described in the text.
The resulting knitted fabric has a good appearance as an interior seating sheet, but no elastic yarn is inserted, and since cushion materials such as urethane are not used, there is no stretch recovery and a large seat Oops. (See Table 3)
[0028]
(Comparative Example 2)
Similarly, using a 9G Russell machine (RM-6F) made of 5 pieces of KARL MAYER, elastic yarns listed in Table 1 are arranged on the front two pieces and polyester yarns shown in Table 2 on the three rear pieces, and knitted. Then, the amount of sinking and the like were evaluated by the method described in the text.
The elastic yarn of L2 is inserted with a swing width between one needle in order to give an extension recovery characteristic, and the elastic yarn of L1 is inserted with a swing width between four needles in order to give an extension recovery characteristic in the weft direction. did. (See Figs. 3 and 4)
The obtained knitted fabric has poor design as an interior seat, and the elastic yarn has a high ratio of direct contact with the human body. Therefore, the seat has a hard seat and is not suitable for long-term use. (See Table 3)
[0029]
[Table 1]

[0030]
[Table 2]

[0031]
[Table 3]

[0032]
【The invention's effect】
According to the present invention, good cushioning performance and seating feeling can be obtained without using a conventional urethane cushion material, which has been regarded as a problem in recent years due to environmental pollution, etc., and recyclable with a design that suits individual tastes. It is possible to provide a stretchable knitted fabric for chair upholstery or vehicle, a manufacturing method thereof, and a sheet forming method.
[Brief description of the drawings]
FIG. 1 is an example of a knitting organization chart of the present invention.
FIG. 2 is an example of a thread placement layout according to the present invention.
3 is a knitting structure diagram of Comparative Example 2. FIG.
FIG. 4 is a layout view of thread insertions in Comparative Example 2;
[Explanation of symbols]
L1: 1st cage, L2: 2nd cage.

Claims (11)

Polyester ester elastic yarns having a breaking elongation (DE) of 50 to 200%, a total denier of 200 to 6000 denier, and a 160 ° C. dry heat shrinkage (SHD) of 12 to 60% are used as the back heel and the total denier is A knitted fabric in which polyester fiber yarns of 100 to 3000 deniers are arranged on the front heel, wherein the knitted fabric has a 10% elongation stress of 30 kgf / 5 cm or less and a breaking strength in both directions of 50 kgf / 5 cm or more. Stretch knitted fabric for interior characterized by that. 2. The stretchable knitted fabric for interior according to claim 1, wherein the polyetherester elastic yarn is a core-sheath type composite elastic yarn. 2. The stretchable knitted fabric for interiors according to claim 1, wherein the polyetherester elastic yarn is fused to an adjacent yarn. The stretchable knitted fabric for interior according to claim 1, wherein a flame retardant and / or a light resistance agent is applied to the polyetherester elastic yarn. The interior according to claim 1, wherein the 160 ° C dry heat shrinkage (SHD) of the polyether ester elastic yarn is 5 to 50% higher than the 160 ° C dry heat shrinkage (SHD) of the polyester fiber yarn. Elastic knitted fabric. A method for producing a stretchable knitted fabric for interior, characterized in that a polyetherester elastic yarn is placed on the back of a warp knitting machine comprising two or more warps and a polyester fiber yarn is placed on the front. . 7. The method for producing a stretchable knitted fabric for interior according to claim 6, wherein at least two front ridges are knitted with a pre-dyed yarn made of polyester-processed yarn. The method for producing a stretchable knitted fabric for interior according to claim 6, wherein a part or all of the polyetherester-based elastic yarn is inserted in a single-swing structure. 7. The method for producing a stretch knitted fabric for interior according to claim 6, wherein a core-sheath type composite elastic yarn and a single component elastic yarn are alternately arranged and knitted as the polyether ester-based elastic yarn. The method for producing a stretchable knitted fabric for interior according to claim 6, wherein heat treatment is performed at a temperature not lower than the melting point on the sheath side and lower than the melting point on the core side of the polyetherester core-sheath type composite elastic yarn after knitting. A method for forming a sheet of a stretchable knitted fabric for interior, wherein the knitted fabric according to claim 1 is tension-fixed on four sides to a frame and then set by applying heat less than the melting point of the polyetherester elastic yarn.

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