JPH07316959A - Corrugated board knit - Google Patents

Abstract

PURPOSE:To obtain a corrugated board knit reduced in fatigue due to repeated loading, excellent in cushioning properties and dyeable by a jet dyeing machine. CONSTITUTION:A polyester-based sheath-core type hot melt yarn having 2 >=180 deg.C hot melt temperature and 150<d>/16f and a polyester false-twisted yarn of 100<d>/34f are doubled and 100time/m twist treatment is applied thereto to form a two folded yarn. A binding thread having 3 to 9 mg/d crimping force can be obtained thereby. A polyester false-twisted yarn of 150<d>/34f is used as the ground yarn of both the face cloth and the lining cloth and joining of the face cloth and the lining cloth is carried out by knitting them with the binding thread using a purl circular knitting machine. After opening, a heat treatment is applied thereto while shrinking it by 18% in the width direction by using a tenter-type dryer to fusion-bond the face cloth to the lining cloth, thus producing the objective corrugated board knit.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cardboard knit used for vehicle seats and the like.

[0002]

2. Description of the Related Art Although cardboard knits are already used in many cases, normal yarn is often used as a connecting yarn (hereinafter abbreviated as "joining yarn") for joining a front material and a lining material. These are mainly used as a lining for clothes and have an effect of imparting appropriate cushioning properties and heat insulating properties.

Also, a cardboard knit using heat-fusible fibers as a joining yarn is already known, for example, Japanese Patent Laid-Open No. 4-2.
There is an example of a knitted fabric molded body described in Japanese Patent No. 4052. This is a molded product that utilizes the stretchability of a knitted fabric and the moldability of a heat-sealing fiber. Therefore, a heat press suitable for moldability, that is, a heat treatment condition by pressure molding is disclosed. However, the purpose is to maintain the shape first, and it is not assumed that a large load is repeatedly applied to the cardboard knit.

On the other hand, as a similar product, a two-layer cotted three-layer structure knitted fabric is already on the market. This knitted fabric uses a monofilament as a joining yarn. The reason for using the monofilament is to improve the cushioning property due to the large elastic modulus. Although this knit is a tricot, it uses spandex in order to impart stretchability in the length and width. Therefore, it is expensive.

However, unlike the tricot, the cardboard knit manufactured by using the circular knitting machine is provided with the stretchability in the longitudinal and lateral directions by the knitting structure without using the spandex.
Unfortunately, a circular knitting machine cannot knit a thick monofilament with a large elastic modulus. Therefore, in cardboard knit, a heat-fusible yarn may be used as a joining yarn that is soft when knitting and has a large elastic modulus when it is made into a product. Therefore, in the case of using a heat-fusible yarn as a joining yarn in a cardboard knit, a manufacturing method is used in which after knitting, the joining yarn is fused by a heat treatment to increase the elastic modulus. However, there is a serious drawback that anti-dyeing cannot be performed if only the heat-fusible yarn is used as the joining yarn. Since the softening point of the heat-fusible yarn is low, wrinkles during dyeing remain and cannot be removed even with finishing.

[0006]

At present, tricots are still used for parts that require high-performance cushioning, such as shoe linings. The reason why ordinary cardboard knits are not used in this field is that they have a large settling force against repeated loading. If a corrugated cardboard knit with a small settling force against repeated loads can be easily manufactured, the cost will be lower than that of a tricot, and the application will be wide. An object of the present invention is to provide an inexpensive corrugated cardboard knit that has a small settling force against repeated loads, has excellent cushioning properties, and can be dyed with a jet dyeing machine.

[0007]

As a result of studying the joining yarn of the cardboard knit and the heat treatment conditions thereof, the present inventors unexpectedly found that heat treatment at a high temperature causes fatigue against repeated loads (hereinafter abbreviated as “sag”). .) May have adverse effects. Further, it has been found that the settling has a minimum value by maintaining the crimp strength due to the combination of the joining yarn and the heat setting within an appropriate range, and the present invention has been completed.

The cardboard knit of the present invention is characterized in that the joining yarn for joining the outer fabric and the lining is composed of a highly crimped yarn and a heat fusion yarn. The crimping force of the joining yarn is preferably 3 to
It is 9 mg / denier.

The fibers used for the front and back of the cardboard knit of the present invention are not particularly limited. That is, commonly used synthetic fibers such as polyester, nylon,
Acrylic, polypropylene, polyethylene filaments and spun yarns are used. Among them, a false twisted textured yarn having elasticity is preferable. Further, spun yarn such as natural fiber, for example, wool, cotton, hemp, etc. can be used. Furthermore, blended yarns of these can also be used. Among them, bulky yarn having elasticity is preferable. For these yarns, it is necessary to select yarns of appropriate thickness depending on the knitting structure and knitting machine. Further, these yarns may be dyed yarns, and the knitting machine may be a jacquard knitting machine, and a pattern may be formed on the front material and the lining material.

Highly crimped yarns for joining include false twisted yarns, different shrinkage mixed yarns, bulky yarns and the like. The false twisted yarn is preferable because it has excellent elasticity and elasticity and is inexpensive. A core / sheath type heat-sealing fiber can be used as the bonding yarn to be heat-sealed.
Further, fibers having a low melting point may be mixed with fibers having a high melting point or natural fibers having no melting point, mixed fibers, mixed twisted yarns, mixed yarns, and mixed fibers for use.

The bonding yarn itself fuses by the heat treatment, but during the heat treatment, it sometimes fuses to the highly crimped yarn, as well as the front and back fabrics. When the fusion-bonded portion of the joining yarn and the same material as the outer material or the backing material contain the same fiber, the joining thread and the outer material or backing material adhere well. This adhesion also affects the fatigue. Therefore, the selection of the splicing yarn, the front material, and the lining material is better when it is selected in consideration of their adhesiveness. Further, in the case of a polymer in which the fused portion is easily fused with other fibers, for example, nylon or polyurethane, the fused portion of the joining yarn adheres even if the same fiber is not contained in the surface or lining. It is preferable for fatigue.

As the heat-bonding yarn of the joining yarn, for example, a filament "bell couple" such as polyester core, low melting point copolyester sheath type LHC, polyester core, nylon sheath type HCC from Kanebo Co., Ltd. It is commercially available. As the heat-sealing fiber for blended yarn, a staple "Belcombi" having polyester as a core, low melting point polyester as a sheath, polyester as a core, and polyethylene as a sheath is commercially available. In addition to these, the heat-sealing fibers for staples are polypropylene homopolymer type PP-HB from Chisso Corporation, polyethylene homopolymer type BF from Daiwa Spinning Co., Ltd., polyester copolymer type 410 from EASTMAN, and side-by-side. Type ES manufactured by Chisso Co., Ltd. having a core of polypropylene and a sheath of polyethylene is commercially available.

As the high-crimped yarn for the joining yarn, for example, as the false twist textured yarn, textured yarns of polyester and nylon are commercially available from Kanebo Co., Ltd. Different shrinkage mixed yarn is also commercially available from Kanebo Co., Ltd. The bulky yarn is a spun yarn obtained by mixing shrinkage cotton and / or conjugate cotton, and imparts bulgy property to the yarn by heat treatment. This is also commercially available from Kanebo Co., Ltd., such as yarn using acrylic fiber. Highly crimped yarns such as the false twisted yarn and the different shrinkage mixed yarn bulky yarn are manufactured by Kanebo Co., Ltd.
Besides, it is commercially available from many domestic and overseas textile manufacturing companies.

The bonding yarn used in the present invention is composed of a high crimped yarn and a heat-fusible yarn, and it is preferable that the heat-fusible yarn is contained in an amount of 10% or more of the weight of the bonding yarn. If the content of the heat-fusible yarn is less than 10%, the cushioning property may be insufficient. It is more preferably 30% or more, and if it exceeds 70%, wrinkles during dyeing tend to remain. Further, when manufacturing a cardboard knit having a large thickness, it is necessary to increase the thickness of the joining yarn, which is not preferable because the cardboard knit becomes expensive.

A cardboard knit with less fatigue can be manufactured by using only the heat-fusible yarns without using the high-crimped yarns as the bonding yarns, but the cardboard knit of the bonding yarns containing only the heat-fusible yarns is generally used. High temperature dyeing is not possible with a simple jet dyeing machine. That is, since the heat-sealed portion has a low softening point, the heat-sealed yarn is softened and deformed during dyeing, and thus wrinkles are generated in the cardboard knit during dyeing. Therefore, it is necessary to use the dyed yarn for the corrugated cardboard knitting yarn which is the joining yarn only of the heat fusion yarn.
Pre-dyed yarn is more expensive than jet dyeing, the process is longer,
There is a drawback that quick delivery is difficult.

By combining the high-crimped yarn and the heat-fusible yarn as the joining yarn, there is little settling and good cushioning property.
A cardboard knit capable of high-temperature dyeing can be produced by a general jet dyeing machine.

The thickness of the joining yarn is generally restricted by the structure of the knitted fabric and the gauge number of the knitting machine. In order to improve cushioning properties and reduce fatigue, it is better that the thickness of the joining yarn is large and the number of yarns per unit area is large.
It is recommended to select it considering the influence on the surface.

When a heat-fusible filament is used as a part of the joining yarn, it is preferable to twist it in order to improve the adhesiveness of the filament itself in order to prevent the settling. A single twisted yarn or a mixed twist may be used. The number of twists depends on the thickness of the yarn, but a twist coefficient of 4 to 10 is preferable. If the twist coefficient is less than 4, the fusion of the bonding yarn itself is insufficient and the settling is not satisfied. If the twist coefficient exceeds 10, the yarn becomes too hard and the texture becomes hard.
Further, twisting more than necessary increases the cost. Here, the twist coefficient represents the thickness of the yarn in denier and is a coefficient by which the square root is multiplied, and the unit is the number of twists per m.

Further, the circular knitting machine usually has a large number of supply ports and supplies a plurality of yarns at the same time. At that time, if the twisting directions S and Z of the joining yarns are supplied so as to be knitted alternately, a cardboard knit having a large thickness can be manufactured without the joining yarns falling over. As a cardboard knitting machine, a commonly used double-sided circular knitting machine may be used. The thickness of the cardboard knit is proportional to the width of movement of the needle, so it is advisable to modify the shuttle if necessary.

The cardboard knit machine is opened and heat set by a tenter dryer. At this time, the thickness can be maintained by appropriately shrinking in the width direction and the machine direction. The width direction is the tenter width, and the machine direction can be adjusted by overfeed.

The temperature and time at the time of heat setting vary depending on the kind of the polymer of the joining yarn and the like, but are usually lower than the heat fusion temperature, preferably about 5 to 45 ° C. lower than the heat fusion temperature. Therefore, it is important for the heat setting temperature to keep the crimping force of the knitting of the joining yarn and the crimping by the heat setting within a certain range. If the crimping force is too large, the heat setting will be too effective and the joining yarn will be too hard. When a repeated load is applied, the hard joining yarn is likely to have strain remaining, resulting in large settling. Further, if the temperature is too low and the heat setting is insufficient, the hardness of the joining yarn becomes insufficient and the cushioning property deteriorates. Since this degree varies depending on the polymer, the thickness of the fiber, the number of constituents, etc., the crimping force of the joining yarn is measured and the heat setting conditions such as the temperature of each room of the tenter, the air volume, the feed speed, etc. can be obtained. It is necessary to select it.

Since the joining yarn used in the cardboard knit of the present invention is a combination of the high crimp yarn and the heat fusion yarn, the heat setting crimp force of the joining yarn is preferably 3 to 9 mg / denier. If the heat-set crimping force of the bonding yarn is less than 3 mg / denier, the cushioning property may be insufficient, and if it exceeds 9 mg / denier, the load tends to be set easily due to repeated loading.
More preferably, it is 4 to 7 mg / denier.

The crimping force of the joining yarn of the cardboard knit of the present invention was obtained by pulling out the joining yarn from the cardboard knit without pulling the joining yarn, measuring the tensile strength with Tensilon, and measuring mg per denier. The crimping force was defined as the strength at 10% lower elongation from the elongation at the inflection point (the point where the crimps are fully extended by the naked eye) where the crimps are fully extended and the SS curve rises. This was set to exclude an abnormal value because the filament length of the multifilament is partially different due to heat fusion, and some fiber elongation is added to the crimp elongation, resulting in an abnormally high value. In addition, in this tensile test measurement, the initial load was set to 1 mg / denier. The sample length was set to be about 3 cm when the initial load was applied.

[0024]

The cardboard knit of the present invention is much cheaper to manufacture than a two-weight cot with similar performance. Also, unlike general corrugated cardboard knits, it has less settling against repeated loads and has excellent cushioning properties. Therefore, not only for clothing, but also for sheet materials,
It is also suitable for lining shoes.

[0025]

EXAMPLES Further details will be described in Examples. The settling was measured according to the repeated compression test of JIS K6401. Since the thickness of one cardboard knit is not enough, stack the samples until the thickness is about 6 cm.
It was used as a measurement sample.

Example 1 Polyester false twisted yarn SD150D / 34F manufactured by Kanebo Co., Ltd. was used as the ground yarns for the front and back fabrics, and the polyester core-sheath type of Kanebo Co., Ltd. was used as the joining yarn at the normal heat fusion temperature of 180 ° C. The above fused thread bell couple, type LCO 150D / 16
F and polyester false twisted yarn SD100D / 34F, twin yarn, 100 twists / m, knitted with a 20 gauge 32 stitch double-sided circular knitting machine, opened, and then 1 in the width direction with a tenter dryer.
While shrinking 8%, the ambient temperature was changed under the conditions of Table 1 and heat fusion was performed for 2 minutes to produce a cardboard knit.
The crimp force of the produced cardboard knit and the crimp force of the joining yarn were measured and shown in Table 1. Further, these cardboard knits were pressure-dyed under the conditions of 130 ° C. and 60 minutes by using a jet dyeing machine by a conventional method. As the disperse dye, Miketone Polyester Scarlet 3RG was used at 4% owf. Bath ratio is 1
The pH was adjusted to 50, and the pH was adjusted to 5 with ammonium acetate and acetic acid. The leveling agent was added at a rate of 1 g / 1. After washing with water and drying with a tenter, the degree of wrinkles was visually evaluated in the order of ⊚, ○, Δ, and ×. Test No. No. 1 lacked in cushioning properties.

[0027]

[Table 1]

Example 2 Test No. 1 of Example 1 In the same manner as in 2, using a polyester core of Kanebo Co., Ltd., a heat-sealing short fiber Bellcombi of polyester sheath, type 4080, 2d, 51 mm as a joining yarn, 1/52 was spun by ordinary 2 inch spinning to yield 70
Spun yarn polyester false twisted yarn SD1 temporarily set at ℃
The cardboard knit of the present invention was manufactured by changing only the draw-aligned compounding yarn of 00D / 34F. The settling rate of this cardboard knit was 5.8% and the crimping force was 6.9 mg / d. As a result of dyeing with a jet dyeing machine in the same manner as in Example 1, the degree of wrinkle was ⊚.

Example 3 Test No. 1 of Example 1 In the same manner as in 2, the joining yarn was made of polyester core of Kanebo Co., Ltd., heat-bonded short fibers of polyester sheath Bell Combi, type 4080, 2d, 51 mm of 50.
% And general polyester, Kanebo type 800,
Spun yarn polyester false twisted yarn SD100D / 34F spun with 50% 1.5D, 51mm, mixed spinning, spun 1/52 by normal 2 inch spinning, and temporarily set at 70 ° C.
The cardboard knit of the present invention was manufactured by changing only the aligned and aligned yarns of No. The settling rate of this cardboard knit is 7.
8% and the crimping force was 3.3 mg / d. As a result of dyeing with a jet dyeing machine in the same manner as in Example 1, the degree of wrinkle was ⊚.

Example 4 Test No. 1 of Example 1 In the same manner as in 2, the thickness of the heat-fusible yarn and the false twisted yarn of the joining yarn was changed, and the compounding ratio (% by weight) was changed only as shown in Table 2 to produce a cardboard knit. The settling rate and the crimping force were measured, and the results are shown in Table 2.

[0031]

[Table 2]

Claims (2)

[Claims] 1. A cardboard knit characterized in that a connecting yarn for joining a surface material and a lining material is a highly crimped yarn and a heat fusion yarn. 2. The cardboard knit according to claim 1, wherein the crimping force of the tether yarn is 3 to 9 mg / denier.