Knitted fabric, fiber product and stuffing

Abstract

To provide a knitted fabric including a chenille yarn that is excellent in heat insulation and suitably used for stuffing of clothing and bedding, and also to provide stuffing.SOLUTION: A knitted fabric includes a chenille yarn. Thickness of the knitted fabric is 10 mm or more. Transmission area percentage of the knitted fabric is 50% or less.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to knitted fabrics, textile products, and stuffed products including molly yarns.

Background Art

[0002] Stuffed products such as clothing and bedding are made by stuffing materials made of natural fibers such as animal fibers and plant fibers, or materials such as synthetic fiber cotton, into bags formed by sewing the lining. The heat inside the stuffed product is difficult to be released to the outside, so that heat retention can be ensured even in a cold environment such as a cold region.

[0003] Feathers, which are representative of natural fibers used for batting, are batting materials having various functions such as a complex structure, hygroscopicity derived from protein fibers, and heat generation. However, from the viewpoint of animal protection, it cannot be washed at home in principle, and above all, since it is composed of protein, it may be difficult to additionally impart desired functions, and the demand for synthetic fiber cotton batting made of synthetic fibers capable of imparting functionality is increasing.

[0004] As synthetic fiber cotton batting, there are many technical proposals in various material forms such as non-woven cotton, granular cotton, and long fiber cotton. Taking advantage of these forms, not only products that simply pursue heat retention, but also the development of products that appeal to comfort and convenience according to the customer's usage is increasing.

[0005] However, in conventional synthetic fiber cotton batting, if there is unevenness in the filling amount in the bag made of the lining, so-called cold spots will occur where the heat inside the stuffed product is released from the coarse part. For this reason, in order to suppress cold spots, a bag formed by sewing on the lining such as a jacket, that is, an excessive amount of synthetic fiber cotton batting is filled with respect to the volume of the down pocket, and it is used so that the batting is kept free of unevenness in the down pocket.

[0006] On the other hand, for long fiber batting made of long fibers, compared with short fiber batting, its movement within the down pocket is suppressed, and cold spots are less likely to form without being overfilled. Especially in knitted fabrics made of moiré yarns with excellent bulkiness, restraint points are formed between adjacent moiré yarns. Therefore, even during actual use or after washing, the batting does not shift, and it is difficult to form unevenness in the batting, which has the advantage of making it easy to control the filling amount of the batting according to the shape of the sewn product.

[0007] There are proposals regarding moiré yarns for such stuffing purposes.

[0008] In Patent Document 1, a soft moiré yarn with excellent bulkiness, cushioning property, resilience, and shape recovery property, and less sagging, and a woven or knitted fabric using the moiré yarn, having extremely excellent texture and excellent cushioning property despite being bulky and lightweight, have been proposed.

[0009] In Patent Document 2, the present inventors proposed a knitted fabric for stuffing, which is made of a moiré yarn with improved bulkiness by using a decorative yarn fused and fixed between the core yarn and the holding yarn of the moiré yarn and having crimps, and is excellent in handling properties and easy-care properties during sewing.

Prior Art Documents

Patent Documents

[0010]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0011] The molle yarn described in Patent Document 1 is bulky when used for decorative yarns, mats, etc. for decorative purposes, and is a material with excellent resilience and recovery. However, since the structure of the yarn part is dense and the amount of air that can be contained inside as a sheet-like material is small, when used as a stuffing for clothing, bedding, etc., the heat retention may be insufficient.

[0012] The knitted fabric made of the molle yarn described in Patent Document 2 is a bulky synthetic cotton in a form that can be used as a fiber product such as clothing and bedding. By using a sheet-like material composed of a knitted fabric, the batting is difficult to move inside the side fabric, and even if it is not filled with a sufficient amount inside the side fabric, it can be in a state where the batting is uniformly filled.

[0013] However, since Patent Document 2 features a structure that emphasizes bulkiness, gaps may be formed between the large protruding yarns. Although it exhibits sufficient heat retention for clothing worn inside an outer such as inner down or for bedding, when used for an outer that is often exposed to outside air, the gaps between these yarns may become fine cold spots and may release heat to the outside. For this reason, there has been a demand for a long fiber batting that can be suitably used for an outer, etc., while maintaining the bulkiness as a batting and suppressing heat release.

Means for Solving the Problems

[0014] In order to solve the above problems, the knitted fabric of the present invention has the following configurations (1) to (6). (1) A knitted fabric containing molle yarn, characterized in that the thickness of the knitted fabric is 10 mm or more and the transmission area ratio of the knitted fabric is 50% or less. (2) The knitted fabric according to (1), characterized in that the knitted fabric is a warp knitting. (3) The knitted fabric according to (1) or (2), characterized in that the yarn of the molle yarn contained in the knitted fabric is a hollow fiber. (4) A fiber product using at least a part of the knitted fabric according to any one of (1) to (3). (5) A stuffing using at least a part of the knitted fabric according to any one of (1) to (3). (6) A stuffing in which two or more knitted fabrics including the mohair yarn are stacked, and in the stacked knitted fabrics, the average value of the distance between the central points of the warp threads is 1 mm or more, which is the stuffing according to (5).

Advantages of the Invention

[0015] The present invention is a knitted fabric capable of effectively suppressing heat release, and can provide fiber products, clothing, and stuffing for bedding with excellent heat retention properties.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Embodiments for Carrying Out the Invention

[0017] Hereinafter, the present invention will be described in detail together with preferred embodiments.

[0018] The knitted fabric of the present invention includes mohair yarn, and an example of the form of the mohair yarn can be exemplified as shown in FIG. 1. For the understanding of the invention, the mohair yarn 6 shown in FIG. 1 shows the state before being fused by the fusing yarn 4 (after being fused by the fusing yarn 4, the core yarn 2, the pressing yarn 3, and the fusing yarn 4 are integrated in part or in whole).

[0019] The moire yarn 6 shown in Fig. 1 sandwiches the fancy yarn 1 between the core yarn 2 and the holding yarn 3 and twists them together, and the fancy yarn 1 is fusion-fixed by the core yarn 2, the holding yarn 3 and the fusion yarn 4. As a form in which the moire yarn is included in the knitted fabric of the present invention, the fancy yarn 1 of the moire yarn 6 is fibrillated and exists in a state of protruding from the surface of the knitted fabric, and it is a knitted fabric of a structure along the moire yarn 6 in the ground yarn that forms the skeleton of the knitted fabric, and the thickness of the knitted fabric needs to be 10 mm or more.

[0020] The knitted fabric of the present invention is used as a stuffing as a sheet-like object. The thicker the knitted fabric, the more air can be held inside the knitted fabric, and high heat retention can be exhibited. From the perspective of promoting this point, the thickness of the knitted fabric is more preferably 15 mm or more, and when it is 20 mm or more, it has heat retention suitable for thermal clothing such as outerwear and bottoms used in extremely cold regions, and in the present invention, it can be cited as a particularly preferable range.

[0021] The thickness of the knitted fabric is appropriately adjusted depending on the application. However, from the viewpoints of cuttability and handleability during product processing, in either case where a single knitted fabric or a plurality of knitted fabrics are stacked and used as one, the thickness is preferably 50 mm or less.

[0022] The knitted fabric of the present invention needs to have a light transmittance area ratio of 50% or less, which is an important requirement. Here, the transmittance area ratio indicates the light transmittance area ratio.

[0023] The so-called stitch-through area ratio of the knitted fabric referred to herein indicates the ratio of the voids existing within the knitted fabric when viewed two-dimensionally from the surface of the knitted fabric, i.e., the voids that become so-called cold spots. For the knitted fabric of the present invention, in order to enhance the heat retention property, in addition to increasing the thickness of the knitted fabric, it is preferable to suppress the heat release from the cold spots and retain the warmed air within the knitted fabric. As a result of intensive studies by the present inventors, it has been found that reducing the above-described through area ratio effectively acts on the heat retention property. That is, by arranging the fibers such that there are few flow paths through which the heat released from the heat source can directly move outward and the heat moving in the thickness direction always hits the fibers, a heat retention portion is formed within the knitted fabric, and the retained air holds the heat, thereby effectively enhancing the heat retention property.

[0024] From this perspective, the through area ratio of the knitted fabric is more preferably 20% or less. As the heat retention portion within the knitted fabric increases, it becomes easier to hold the warmed air even at a position close to the heat source, thereby enhancing the heat retention property. Further, it is even more preferable to set the through area ratio of the knitted fabric to 10% or less. In this case, since the heat release is greatly suppressed, the effect of heat retention in the air layer formed in the knitted fabric becomes remarkable, and high heat retention can be obtained even when the knitted fabric has no thickness. For example, it can be suitably used for heat retention sportswear that also emphasizes ease of movement.

[0025] The through area ratio of the knitted fabric in the present invention can be determined from an image obtained by taking a through-shot two-dimensionally from the surface of the knitted fabric. In order to obtain the above-described through-shot image, for example, the knitted fabric is placed on a light source such as a tracing table having an illuminance of 2000 lux or more, and the knitted fabric is photographed from above. The observation magnification may be any magnification at which each part can be clearly confirmed. Further, the observation field of view may be any field of view that includes two or more warp and weft stitches of the knitted fabric structure.

[0026] For the said image, using image processing software, perform binarization processing at a threshold value at which the contours of each part can be discriminated between the fiber part and the void part, and calculate the area ratio of the void part. Here, it is possible to use general image processing software for the binarization processing, and examples of such software include WinROOF (manufactured by Mitani Shoko Co., Ltd.). The above operations were performed on 10 images taken, and the average value of the 10 images was taken as the transmission area ratio (%) of the knitted fabric in the present invention.

[0027] In the present invention, from the viewpoint of increasing the thickness of the knitted fabric, the fabric structure is preferably a warp knitting structure that suppresses the moiré fancy yarn 1 from being caught in the stitches and makes it easy for the fancy yarn 1 to protrude. Here, the warp knitting structure has appropriate stretchability and dimensional stability, and is also suitable in terms of excellent wearability and comfort when used as a fiber product such as clothing or bedding. Among warp knitting, raschel knitting is more preferable as it is easy to form a low-grammage knitted fabric. Further, as a structure that can efficiently protrude the fancy yarn 1, single raschel knitting is even more preferable. By having the fancy yarn 1 protrude on both sides of the knitted fabric, the excluded volume by the fancy yarn 1 can be increased, and it is easy to increase the thickness of the knitted fabric.

[0028] Figure 2 is a schematic diagram for explaining the fabric structure.

[0029] In Figure 2, as an example of the knitted fabric of the present invention, the structure of single raschel knitting is shown, and the ground yarns 5a, 5b, 5c, 5d are warp yarns. The moiré 6 is, for example, knitted in the warp direction along the ground yarn 5b that is chain knitted, and then crosses over to the adjacent ground yarn 5c at the yarn crossing position 9 to form the weft yarn. Subsequently, after being knitted in the warp direction along the ground yarn 5c, it returns to the ground yarn 5b to form a lattice-like stitch. By using such a fabric structure, the morphological stability can be enhanced, bias is less likely to occur during washing or with use over time, and uniform heat retention can be maintained in each part of the product.

[0030] In the knitted fabric of the present invention, it is preferable in terms of protruding the fancy yarn 1 that at least one of the lengths of one side of the stitch is larger than the fancy yarn protruding length 8.

[0031] By making the yarn protrusion length 8 of the mohair 6 greater than at least one side of the stitch (the stitch warp side length 7a or the stitch weft side length 7b), when knitting the knitted fabric, the yarn 1 of the mohair 6 is suppressed from being caught in the stitches, which effectively acts to reduce the transmission area ratio of the knitted fabric. In addition, since the yarn 1 of the mohair 6 can be used efficiently, even when making a low-grammage knitted fabric, it is possible to secure a sufficient thickness of the knitted fabric for use as a stuffing and enhance the heat retention property.

[0032] It is preferable that the mixing ratio of the mohair 6 in the entire knitted fabric of the present invention is 85% by mass or more. This mixing ratio of the mohair is more preferably 90% by mass or more. If it is within such a range, it is easy to secure thickness due to the protrusion of the yarn 1 of the mohair 6 used in the knitted fabric of the present invention, and it is easy to obtain a knitted fabric with high heat retention even with a low grammage.

[0033] The knitted fabric of the present invention preferably has a grammage of 10 g / m 2 or more and 300 g / m 2 or less. When the grammage of this knitted fabric is 10 g / m 2 or more, the yarn 1 can appropriately fill the space, thereby reducing the transmission area ratio of the knitted fabric. Also, when the grammage is 300 g / m 2 or less, it also has excellent handleability and comfort when made into fiber products such as clothing and bedding. The grammage is more preferably 15 g / m 2 or more and 200 g / m 2 or less. As the number of yarns 1 increases, the transmission area ratio of the knitted fabric can be further reduced, the heat retention property of the knitted fabric is enhanced, and the lightness is increased, thereby further improving the comfort during wearing. Furthermore, as the heat retention property is improved, and as a range that is also excellent for carrying the product, etc., the grammage is more preferably 20 g / m 2 or more and 150 g / m 2 or less.

[0034] The yarns constituting the knitting of the present invention are preferably composed of synthetic fibers. The synthetic fibers mentioned here are fibers made of synthetic polymers (hereinafter referred to as "polymers"), and fibers made of thermoplastic polymers manufactured by melt spinning, solution spinning, etc. can be adopted. The fibers may be single-component fibers or composite fibers in which two or more polymers are arranged in the fiber cross-section.

[0035] Examples of the thermoplastic polymers constituting the fibers include polyesters such as polyethylene terephthalate or its copolymers, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyamides such as nylon 6, nylon 66, nylon 610, polyolefins such as polyethylene, polypropylene, polycarbonate, polyacrylate, polylactic acid, and melt-moldable polymers such as thermoplastic polyurethane. Among these thermoplastic polymers, polycondensation polymers typified by polyesters and polyamides have crystallinity and relatively high melting points, so they are suitable examples even when heated at relatively high temperatures during heat treatment processes and actual use (such as cleaning) in post-processing, etc., without causing deterioration or sagging. From the viewpoint of this heat resistance, it is particularly preferable that the melting point of the polymer is 165 °C or higher.

[0036] These thermoplastic polymers may contain various additives such as inorganic substances such as titanium oxide, silica, barium oxide, colorants such as carbon black, dyes and pigments, flame retardants, fluorescent brighteners, antioxidants, or ultraviolet absorbers, as long as the effects of the present invention are not impaired.

[0037] As the ground yarn, in order to be excellent in handleability such as being difficult to break during knitting and being difficult to break when pulling out a knitted fabric containing the mall yarn 6 from a roll fabric, a packing bag, etc. when filling the lining as a stuffing, polyamides such as polyethylene terephthalate, nylon 6, nylon 66, nylon 610, etc. are exemplified. Further, those excellent in the tensile strength of the fiber are preferable, and polyamide is more preferable. In the present invention, from the viewpoint of reducing the transmission area ratio of the knitted fabric, in order to increase the mixing ratio of the mall yarn 6 and increase the number of the pattern yarns 1, it is preferable to lighten the ground yarn, and it is more preferable that the ground yarn is nylon 6.

[0038] The mall yarn 6 of the present invention is a processed yarn in which the pattern yarn 1 is sandwiched between the core yarn 2 and the pressing yarn 3 and twisted together as shown in FIG. 1, and the pattern yarn 1 is fusion-fixed.

[0039] In the specification of the present invention, when explaining the structure of the mall yarn 6, there is also a part where the state in which the core yarn 2, the pressing yarn 3, and the fusion yarn 4 are twisted together is shown as the core yarn. It is preferable that the pattern yarn 1, the core yarn 2, and the pressing yarn 3 constituting the mall yarn 6 of the present invention are made of the above-mentioned synthetic fiber.

[0040] As the pattern yarn 1 of the mall yarn 6 contained in the knitted fabric of the present invention, in order to increase the thickness of the knitted fabric so that a large amount of air with a low thermal conductivity can be retained inside the knitted fabric, it is preferable to use a fiber excellent in rigidity that allows the pattern yarn 1 to protrude easily, and polyester is preferable. Among polyesters, from the viewpoint of heat resistance similar to that of the core yarn 2 and the pressing yarn 3, polyethylene terephthalate is more preferable.

[0041] Regarding the decorative yarn 1 of the mohair 6 included in the knitted fabric of the present invention, in order to increase the thickness of the knitted fabric, it is preferably a fiber having a shape that easily increases the volume per fineness, has a hollow part in the fiber cross-section, and is preferably a hollow fiber in which the hollow part is continuous in the length direction of the fiber. Here, considering the prevention of sagging, which is a factor in the reduction of heat retention during washing and with practical use over time, it is preferable that the mass of the decorative yarn 1 itself is small in order to reduce the load due to its own weight. From the viewpoint of light weight, it is preferably a hollow fiber having a hollow ratio of 10% or more.

[0042] The hollow ratio mentioned here is the volume ratio of the part where the polymer does not exist in the fiber and can be measured, for example, by the following method.

[0043] After cutting the decorative yarn 1 so that its cross-section can be observed, the fiber cross-section is photographed with a scanning electron microscope (SEM) at a magnification at which the cross-sections of 10 or more single fibers can be observed. Ten single fibers randomly selected from the photographed image are extracted, the equivalent circle diameters of the fiber and the hollow part are measured using image processing software, and the area ratio of the hollow part is calculated therefrom. The above operations are performed on the 10 photographed images, and the average value of the 10 images is taken as the hollow ratio of the hollow fiber of the present invention.

[0044] In the case of a hollow fiber with a round cross-section, there is the following simple method for evaluating the hollow ratio. Observe the side surface of the hollow fiber with a magnifying means such as a microscope, and measure the fiber diameter in terms of a round cross-section from the image. It is also possible to calculate the ratio of the actually measured fineness to the fineness of the non-hollow fiber calculated from this fiber diameter and the material density of the fiber as the hollow ratio.

[0045] From the perspective of excellent heat retention, which is an object of the present invention, it is preferable that the fiber used for the fancy yarn 1 also contains a large amount of air, and the hollowness ratio is more preferably 20% or more. Within the above range, in addition to excellent heat retention, it is also possible to experience good lightness as a knitted fabric. Further, in order to contain more air, the hollowness ratio is more preferably 30% or more. From such a perspective, the higher the hollowness ratio, the more preferable it is. However, in the yarn manufacturing process and the processing process of the mohair yarn, the upper limit value of the hollowness ratio in the present invention is preferably set to 50% as a range in which the collapse of the hollow part is less likely to occur and stable production is possible.

[0046] The cross-section of the hollow fiber may be a round cross-section, but it is more preferable to use a fiber having an irregular cross-section such as a Y-shape, a multi-lobe shape, a flat shape, a multi-fin shape, etc., which is a shape that is lightweight and easy to increase the volume, and includes a hollow part. By using such a fiber, in addition to the hollow part inside the fiber, air can also be retained in the voids formed between adjacent single filaments due to the unevenness provided outside the fiber, which is preferable from the perspective of further enhancing the heat retention.

[0047] The fancy yarn 1 of the mohair yarn 6 contained in the knitted fabric of the present invention preferably has crimps. This crimp indicates that the fancy yarn 1 has a three-dimensional spiral structure. Fibers having such a spiral structure similar to a spring have resilience and repellency against elongation deformation and compression deformation. By having such a structure, the fancy yarns also repel each other between the single filaments of the fancy yarn, and the fancy yarn 1 is easily fibrillated for each single filament, and the tips of the fancy yarn 1 tend to face in all directions of the cross-section perpendicular to the longitudinal direction of the mohair yarn 6. As a result, the excluded volume as the mohair yarn 6 increases, it is easy to increase the thickness of the knitted fabric, leading to an improvement in heat retention.

[0048] Further, the repellency of the mohair yarn 6 exhibits a good touch as a filling material, and also from the perspective of preventing sagging and suppressing a decrease in heat retention over time in practical use, when repeated compression recovery is applied, the fancy yarn 1 supporting this recovers like a spring, which is also preferable.

[0049] In the present invention, in order to enhance the heat retention property of the knitted fabric, as described above, hollow fibers are preferably used as the decorative yarns 1 of the mohair yarn 6. By performing asymmetric cooling during spinning of the hollow fibers, it is easy to cause a fiber orientation difference due to the cooling difference in the fiber cross-section, and it is easy to obtain fibers having apparent crimp even with a single component. The degree of apparent crimp in this case is a loose crimp on the order of several tens of mm as the radius of curvature. However, at the time of processing the mohair yarn 6, since the single yarns of the decorative yarn 1 are easily split, it becomes easy to increase the thickness of the knitted fabric and effectively acts to reduce the transmission area ratio of the knitted fabric.

[0050] The crimp obtained by such asymmetric cooling can be appropriately adjusted particularly by the cooling conditions immediately after discharge and the draw ratio during spinning.

[0051] The decorative yarn 1 of the mohair yarn 6 included in the knitted fabric of the present invention preferably has 10 or more and 100 or less single filament yarns. By setting the number of single filament yarns of the decorative yarn 1 within the above range, it is difficult to inhibit the splitting of the single yarn of the decorative yarn 1, and it becomes easy to uniformly disperse and arrange the decorative yarn 1 in the voids of the knitted fabric. From the viewpoint of promoting the splitting of the single yarn of the decorative yarn 1 and dispersing the decorative yarn 1 as a whole without unevenness, it is more preferable that the number of single filament yarns of the decorative yarn 1 is 15 or more and 80 or less. Further, in order to include a well-balanced range including increasing the thickness of the knitted fabric, it is more preferably 20 or more and 60 or less.

[0052] The decorative yarn 1 of the mohair yarn 6 included in the knitted fabric of the present invention preferably has a total fineness of 70 dtex or more and 400 dtex or less. By setting the total fineness of the decorative yarn 1 within the above range, when it is used as a stuffing, it has sufficient resistance to support the side fabric and it becomes easy to ensure the thickness of the product. The total fineness of the decorative yarn 1 is more preferably 80 dtex or more and 350 dtex or less, and a lightweight and thick product can be obtained. Further, from the viewpoint of further enhancing the recovery property immediately after taking out from the stored state and exhibiting excellent heat retention property immediately after wearing, the total fineness of the decorative yarn 1 is more preferably 85 dtex or more and 300 dtex or less.

[0053] In the present invention, the core yarn 2 and the pressing yarn 3 may be the same yarn or different yarns. For example, when two identical yarns are used, in the present invention, one is the core yarn 2 and the other is the pressing yarn 3. The core yarn 2 and the pressing yarn 3 may be a ply yarn of a plurality of yarns.

[0054] In the present invention, it is preferable that the decorative yarn 1 is fusion-fixed between the core yarn 2 and the pressing yarn 3. In the moire yarn 6 of FIG. 1, both the core yarn 2 and the pressing yarn 3 do not have fusibility, and the fusion yarn 4 is used together with the core yarn 2 and the pressing yarn 3 to fusion-fix the decorative yarn 1. However, without using the fusion yarn 4, the decorative yarn 1 may be fusion-fixed by making either or both of the core yarn 2 and the pressing yarn 3 into fusible yarns.

[0055] As the core yarn 2 and the pressing yarn 3 used for the moire yarn 6 of the present invention, those having excellent handleability such as being difficult to break during knitting and being difficult to break when pulling out a knitted fabric including the moire yarn from a roll fabric or a packaging bag when filling the side fabric as a stuffing are preferable. Those having excellent tensile strength of the fiber are suitable, and polyester or polyamide is preferable. Further, from the viewpoint of imparting flexibility as a moire yarn in addition to the tensile strength, polyamides such as nylon 6, nylon 66, and nylon 610 are more preferable. From the viewpoint of heat resistance when fusion-fixing the decorative yarn and from the viewpoint of maintaining appropriate resilience even when repeated deformation is applied, nylon 66 is even more preferable.

[0056] In the moire yarn 6 of the present invention, it is preferable that the decorative yarn 1 is sandwiched between the core yarn 2 and the pressing yarn 3 and fusion-fixed. By sandwiching and fusion-fixing the decorative yarn 1 between the core yarn 2 and the pressing yarn 3, the dropping of the decorative yarn 1 during knitting and the dropping of the decorative yarn 1 during pulling out when filling as a stuffing are suppressed, leading to an improvement in the handleability of the moire yarn 6.

[0057] As for the core yarn 2 and the holding yarn 3, when the core yarn 2 has fusibility or the holding yarn has fusibility, it is preferable that they remain inside the moire yarn 6 as the core yarn or the holding yarn even after fusion fixing, and sandwich the decorative yarn 1. It is preferable to use a core-sheath type composite fiber in which the core is made of a high melting point component and the sheath is made of a low melting point component. Further, when the core yarn 2 and the holding yarn 3 do not contain a fusing component, it is preferable to supply one or both of them to a twisting machine with a fusing yarn 4 attached. As the fusing yarn 4 in this case, a single-component fiber composed of the above-mentioned core-sheath type composite fiber, a polyester-based low melting point polymer, and a polyamide-based low melting point polymer can be given as a preferable example. Further, in order to firmly adhere and fix the decorative yarn 1, a single-component fusing fiber composed only of a fusing component is more preferable. Further, in order to ensure the thickness of the knitted fabric as in the present invention, it is preferable to suppress excessive shrinkage of the decorative yarn 1 itself, and those that can achieve fusion fixing by low-temperature and short-time treatment are suitable. From this viewpoint, a single-component fusing fiber made of a polyamide-based low melting point polymer is more preferable.

[0058] The moire yarn 6 included in the knitted fabric of the present invention preferably has a decorative yarn protruding length 8 of 10 mm or more. When the protruding length of the decorative yarn 1 is within the above range, the tips of the decorative yarn 1 can be arranged so as to face in all directions in the yarn cross-section of the moire yarn 6, increasing the excluded volume per strand of the moire yarn 6 and making it easier to thicken the thickness of the knitted fabric.

[0059] As a range that has a good balance with the degree of fibrillation of the decorative yarn 1 and effectively contributes to increasing the thickness, the decorative yarn protruding length 8 is more preferably 12.5 mm or more and 20 mm or less, and even more preferably 13.5 mm or more and 17.5 mm or less.

[0060] This decorative yarn protruding length 8 can be confirmed by unwinding the decorative yarn 1 wound around the core yarn 2 of the moire yarn 6, directing it in a direction perpendicular to the length direction of the core yarn 1, stretching and fixing the decorative yarn 1, and measuring the length of the decorative yarn 1.

[0061] In the mohair yarn 6 included in the knitted fabric of the present invention, the interval between the fusion fixing positions of the fancy yarn 1 sandwiched between the core yarn 2 and the pressing yarn 3 is preferably 1.0 mm or more and 4.0 mm or less. When the interval of the fancy yarn 1 is within the above range, the fancy yarn 1 having crimps does not overlap excessively, and the single filaments are moderately wound around the core yarn in a state where they are fibrillated, and the tips of the fancy yarn 1 can be made to protrude more in the outer circumferential direction in the yarn cross-section of the mohair yarn 6. By arranging the fancy yarn 1 in this way, the protrusion of the fancy yarn 1 in the thickness direction of the knitted fabric increases, and it becomes easier to thicken the thickness of the knitted fabric.

[0062] From such a viewpoint, the interval between the fusion fixing positions of the fancy yarn 1 is more preferably 1.3 mm or more and 3.5 mm or less, and even more preferably in the range of 1.5 mm or more and 3.0 mm or less.

[0063] Figure 3 is a schematic diagram for explaining the interval between the fusion fixing positions of the fancy yarn 1 of the mohair yarn 6 included in the knitted fabric of the present invention. As shown in Figure 3, the interval 10 between the fusion fixing positions of the fancy yarn 1 is obtained by unwinding the fancy yarn 1 wound around the core yarn 2 of the mohair yarn 6, directing it in a direction perpendicular to the core yarn 2, and observing at a magnification at which at least two points where the fancy yarn 1 is sandwiched between the core yarn 2 and the pressing yarn 3 can be confirmed using a digital microscope or the like. Using this observation image, the interval 10 between the fusion fixing positions of the fancy yarn can be confirmed by measuring the two-point distance from the center point of the fancy yarn 1 at the fusion position to the center point of the adjacent fancy yarn 1.

[0064] In the present invention, the mohair yarn 6 can be manufactured using a conventionally known mohair yarn twisting machine, and for example, it is possible to use a mohair yarn twisting machine as shown in Japanese Patent Laid-Open No. 53-6642.

[0065] The knitted fabric of the present invention can be used in various forms and can be made into various fiber products. Examples of the fiber products mentioned here include general clothing, sports clothing, clothing materials, bedding such as futons and mattress pads, thin blankets, sleeping bags, carpets, sofas, interior products such as curtains, various decorative materials, stuffed toys, and vehicle interior products such as car seats.

[0066] In addition to retaining air due to its thickness, the knitted fabric of the present invention can effectively suppress heat transfer in the thickness direction, so it is preferably used in a sheet form and filled in products, and is preferably used as a filling for clothing and bedding.

[0067] Here, when the knitted fabric of the present invention is used as a filling, it is preferably used as a filling in which two or more knitted fabrics are stacked. By stacking the knitted fabrics of the present invention, the yarns 1 repel each other between the overlapping knitted fabrics, making it easier to increase the thickness of the knitted fabric. Also, since the yarns 1 are mixed with each other between adjacent knitted fabrics, the dispersion direction of the yarns 1 existing in the voids of the knitted fabric becomes complicated, which is also preferable in that it is easy to reduce the transmission area ratio of the knitted fabric.

[0068] The greater the number of stacked knitted fabrics of the present invention, the easier it is to obtain the above-described effects, and a filling having more excellent heat retention properties can be obtained. From this viewpoint, the number of laminated sheets is more preferably 3 or more, and even more preferably 5 or more. On the other hand, as the number of laminated knitted fabrics increases, the compression due to the self-weight of the knitted fabric also increases, and the mass as a filling also becomes heavier. Therefore, the upper limit of the number of laminated sheets is 10.

[0069] When the knitted fabric of the present invention is stacked and used as a filling, as the laminated knitted fabric, it is preferable that the average value of the center point distances between warp threads is 1 mm or more. The center point distance between the above-described warp threads indicates that the knitted stitches of the stacked knitted fabrics are laminated in a shifted state. By stacking the knitted fabrics in this way, the transmission area ratio of the knitted fabric can be effectively reduced, which is preferable.

[0070] In the present invention, the center point distance between warp threads can be confirmed by measuring the distance between warp threads using image processing software in the binarized image used when calculating the above-described transmission area ratio.

[0071] At least 10 locations of the laminated knitted fabric were photographed, the distance between warp threads was measured in each image, and the average value was taken as the center point distance (mm) between warp threads in the present invention.

[0072] In the present invention, it is possible to easily adjust the areal density, bulkiness, etc. of the knitted fabric according to the intended use and performance. In addition to the knitted fabric of the present invention, it can also be used in combination with other batting materials that can be used for stuffing, and a stuffing having material characteristics other than the knitted fabric of the present invention can be obtained.

Examples

[0073] Hereinafter, the knitted fabric of the present invention and its effects will be specifically described with reference to examples. In the examples and comparative examples, the following evaluations were performed.

[0074] A. Fineness The mass of 1 m of the fiber and the mohair yarn was measured, and the fineness was calculated by multiplying it by 10,000. This was repeated 10 times, and the value obtained by rounding off the first decimal place of the simple average value was taken as the fineness (dtex) of the fiber.

[0075] B. Areal density of the knitted fabric The knitted fabric was evenly spread out so that the knitting (warp and weft) was perpendicular, cut into a 1 m square, and the mass was measured. This was repeated at 10 locations, and the value obtained by rounding off the first decimal place of the simple average value was taken as the areal density of the knitted fabric (g / m 2 )

[0076] C. Thickness of the knitted fabric A test piece cut into a 10 cm square was prepared with the knitting (warp and weft) of the knitted fabric evenly spread out so that it was perpendicular, and a 10 cm square thin plate (initial load 0.025 g / cm 2 ) was placed on it. After 1 minute, the height of the four corners of the thin plate was measured, and the average value was calculated. For each sample, the measurement was repeated 5 times, and the value obtained by rounding off the first decimal place of the simple average value was taken as the thickness of the knitted fabric (mm).

[0077] D. Transmittance area ratio of the knitted fabric, distance between the center points of the warp A knitted fabric was placed on a light source (LED tracing table "Light Table Plus" manufactured by Banco Co., Ltd.), illuminated from below, and photographed at a magnification of 10 using a digital microscope ("VHX-2000" manufactured by Keyence Corporation) from above to obtain an image of the knitted fabric.

[0078] Regarding the said image, using image processing software ("WinROOF" manufactured by Mitani Shosha Co., Ltd.), binarization processing was performed between the fiber part and the void part at a threshold value at which the contours of each part could be discriminated, and the area ratio of the void part was calculated. The above operations were performed on 10 images taken, and the value obtained by rounding the first decimal place of the average value of the 10 images was taken as the transmission area ratio (%) of the knitted fabric.

[0079] Also, in the said image, the distance between the center points of the warp threads was measured. Regarding the 10 images taken, the distance between the center points of the warp threads was measured at two locations respectively, and the value obtained by rounding the first decimal place of the average value of the 20 points was taken as the distance between the center points of the warp threads (mm).

[0080] E. Heat retention (clo value) Using a commercially available 40d (denier) nylon fabric for the outer and inner fabrics, filling with the knitted fabric of the present invention, quilting was performed in parallel in one direction with a quilt pitch of 10 cm, and the fabric edges were sewn to produce a 40 cm square cushion.

[0081] Using the said cushion, the clo value of the cushion was measured using a heat retention tester ("AW-2" manufactured by Intec Co., Ltd.) incorporated with software corresponding to the ASTM D 1518-85 standard.

[0082] (Example 1) <Core yarn, pressing yarn, fusing yarn> As the core yarn and the pressing yarn, one each of nylon 66 fibers (product name "Promilan" (registered trademark) total fineness 44 dtex - 34 filaments (hereinafter expressed as 44T - 34f) manufactured by Toray Industries, Inc.), and as the fusing yarn, a polyamide-based fusing fiber (copolymer polyamide fiber: product name "Elder" (registered trademark) 22T - 10f manufactured by Toray Industries, Inc.) was used.

[0083] <Pattern yarn> After melting polyethylene terephthalate (PET: intrinsic viscosity IV = 0.6 dl / g, crystallization temperature 150 °C) at 290 °C, it was metered with a gear pump, flowed into a spinning pack, and discharged from a hollow cross-section discharge hole where three slits (width 0.1 mm) were arranged concentrically. After spraying cooling air at 20 °C on the discharged yarn at a flow rate of 30 m / min from one side for cooling and solidification, a spinning finish was applied and an undrawn yarn was wound up at a spinning speed of 1500 m / min. Subsequently, two hollow fibers (44T - 12f, hollowness ratio 30%) made of polyethylene terephthalate, which were obtained by stretching the wound undrawn yarn at a stretching speed of 800 m / min between rollers heated to 90 °C and 140 °C, were combined and used as fancy yarns.

[0084] <Moire yarn> Using a conventionally known moire twisting machine, with the ratio of the supply speed of the core yarn and the holding yarn to the supply speed of the fancy yarn being 1:19, the fancy yarn was supplied to the flyer part, a fused yarn was attached to the holding yarn, and the core yarn and the holding yarn were supplied from two directions. The fancy yarn was wound around a guide piece with a width of 30 mm at the lower end, the fancy yarn was cut with a cutter and sandwiched between the core yarn and the holding yarn, and the twist was adjusted to 250 turns per meter (T / m) for twisting and then wound up with a spindle.

[0085] Subsequently, the moire yarn was wound in a skein at 200 g each using a skein winding machine, the skein was hooked on a rod of a transport cart equipped with a skein hanging rod, and then put into a pressurized steam heat treatment furnace, and a pressurized steam treatment was performed at 98 °C for 20 minutes to melt the fused yarn and fix the fancy yarn to obtain a moire yarn. The obtained moire yarn was cut into 1 m lengths and weighed, and the fineness was calculated by multiplying this by 10000. This measurement was repeated 10 times, and the fineness of the moire yarn obtained by rounding the first decimal place of the simple average value was 1752 dtex.

[0086] <Fabric> Using moire yarn and 44T - 10f nylon 6 fibers as ground yarns, knitting was performed using a conventionally known single raschel knitting machine (manufactured by Karl Mayer) with the number of warp needles adjusted to 1G, and the areal density was 17 g / m 2A knitted fabric was obtained. This knitted fabric was shifted by about half of the stitch in both the warp and weft directions and overlapped, with a total basis weight of 34 g / m 2 The resulting product was used as the knitted fabric of Example 1.

[0087] Regarding the knitted fabric of Example 1, the distance between the central points of the warp threads was 12 mm and they overlapped, the thickness was 11 mm, and the transmission area ratio was 26%. The clo value of the zabuton made using the knitted fabric of Example 1 was 0.71, showing a light weight feeling with a low basis weight and excellent heat retention. The results are shown in Table 1.

[0088] (Examples 2, 3) The number of layers of the knitted fabric of Example 1 was changed as shown in Table 1.

[0089] Example 2 is a product with 4 layers of knitted fabric, with a total basis weight of the knitted fabric of 68 g / m 2 , the distance between the central points of the warp threads was 6 mm and they overlapped, the thickness was 17 mm, and the transmission area ratio was 14%. It was a knitted fabric with a greater thickness and a smaller transmission area ratio than Example 1. The clo value of the zabuton made using the knitted fabric of Example 2 was 0.92, showing a light weight feeling and being more excellent in heat retention than Example 1. The results are shown in Table 1.

[0090] Example 3 is a product with 6 layers of knitted fabric, with a total basis weight of the knitted fabric of 102 g / m 2 , the distance between the central points of the warp threads was 3 mm and they overlapped, the thickness was 23 mm, and the transmission area ratio was 9%. It was a knitted fabric with a greater thickness and a smaller transmission area ratio than Example 2. The clo value of the zabuton made using the knitted fabric of Example 3 was 1.24, showing very excellent heat retention. The results are shown in Table 1.

[0091] (Examples 4, 5) Using the mohair yarn of Example 1, the folding frequency of the mohair yarn during raschel knitting was increased by 2 times to make the basis weight of the knitted fabric 37 g / m 2 The resulting product was used as the knitted fabric of Example 4.

[0092] Example 4 is a product with 2 layers of knitted fabric shifted by about half of the stitch in both the warp and weft directions, with a total basis weight of 74 g / m 2was used.

[0093] Regarding the knitted fabric of Example 4, the distance between the center points of the warp threads overlapped was 12 mm, the thickness was 14 mm, and the transmission area ratio was 11%. The clo value of the zabuton made using the knitted fabric of Example 4 was 0.97, showing a feeling of lightness and excellent heat retention. The results are shown in Table 1.

[0094] In Example 5, three layers of knitted fabric were stacked, with a total basis weight of 111 g / m 2 was used.

[0095] Regarding the knitted fabric of Example 5, the distance between the center points of the warp threads overlapped was 7 mm, the thickness was 20 mm, and the transmission area ratio was 5%. The clo value of the zabuton made using the knitted fabric of Example 5 was 1.28. Although the thickness was thinner than that of Example 3 with the same basis weight, it had very excellent heat retention. The results are shown in Table 1.

[0096] (Example 6) Using the mohair yarn of Example 1, the folding frequency of the mohair yarn during the Raschel knitting was increased by 5 times, and the basis weight of the knitted fabric was 105 g / m 2 was used.

[0097] In Example 6, one layer of knitted fabric was used. The thickness of the knitted fabric was 10 mm, and the transmission area ratio was 21%. Although the part where the fancy yarn of the mohair yarn was caught in the stitches was visible, it was a knitted fabric with thickness even with a single layer and a small transmission area ratio. The clo value of the zabuton made using the knitted fabric of Example 6 was 0.81, showing a feeling of lightness and excellent heat retention. The results are shown in Table 1.

[0098] (Example 7) When spinning polyethylene terephthalate fibers for use in floral threads, the spinneret was changed to a 24-hole round cross-section spinneret and spun in the same manner as in Example 1, followed by drawing to obtain fibers (44T-12f) made of polyethylene terephthalate. The two fibers were combined into a floral thread and used as such. The introduction interval of the floral thread was adjusted so that the yarn count of the moire yarn was the same as in Example 1 to obtain a moire yarn. The yarn count of the obtained moire yarn was 1756 dtex.

[0099] Subsequently, in the same manner as in Example 1, knitting was performed using a single raschel knitting machine to obtain a knitted fabric with a basis weight of 17 g / m. 2 This knitted fabric was shifted by about half of the stitch in both the warp and weft directions and overlapped to obtain a fabric with a total basis weight of 34 g / m, which was used as the knitted fabric of Example 7. 2 For the knitted fabric of Example 7, the distance between the center points of the warp was 12 mm and they overlapped, the thickness was 11 mm, and the transmission area ratio was 28%. The clo value of the zabuton made using the knitted fabric of Example 7 was 0.65. It had a low basis weight, a lightweight feeling, and excellent heat retention properties. The results are shown in Table 1.

[0100] (Example 8)

[0101] For the floral thread, polyethylene terephthalate (PET, intrinsic viscosity IV 0.6 dl / g, crystallization temperature 150°C) was melted at 290°C, metered by a gear pump, and introduced into a spinning pack. It was discharged from a hollow cross-section discharge hole in which three slits (width 0.1 mm) were arranged concentrically. The discharged yarn was blown with cooling air at 20°C at a flow rate of 30 m / min from one side for cooling and solidification, and then a spinning finish was applied and the undrawn yarn was wound up at a spinning speed of 1500 m / min. Subsequently, the wound undrawn yarn was drawn at a draw speed of 800 m / min between rollers heated to 90°C and 140°C to obtain hollow fibers (40T-12f, hollowness ratio 30%) made of polyethylene terephthalate, and four of them were combined and used.

[0102] Also, the core yarn and the holding yarn were the same as in Example 1, and a polyamide-based fusible fiber (copolymer polyamide fiber: trade name “Elder” (registered trademark) 78T-24f manufactured by Toray Industries, Inc.) was used as the fusible yarn.

[0103] In the processing of the moiré yarn, the twist per meter was adjusted to 600 T / m and twisted together, and then wound up with a spindle. Subsequently, a pressure steam treatment was performed in the same manner as in Example 1 to melt the fused yarn and obtain a moiré yarn in which the fancy yarn was fused and fixed. The fineness of the obtained moiré yarn was 3475 dtex.

[0104] Using the moiré yarn of Example 8, the ground yarn was made the same as in Example 1 and knitted with a conventionally known circular knitting machine (knitting cylinder diameter of about 75 cm, 7 gauge). Regarding the fabric structure, in the wale direction of the fabric, the insertion ratio of the moiré yarn to the ground yarn was 1:1, that is, intarsia knitting was performed so that one moiré yarn was inserted for every one ground yarn inserted, and a fabric with a basis weight of 158 g / m 2 was obtained.

[0105] Regarding the fabric of Example 8, the thickness was 12 mm, the transmission area ratio was 4%, and it was a fabric based on a weft knitting structure, but it had a thick thickness and a small transmission area ratio.

[0106] The seat cushion made using the fabric of Example 8 had a certain heaviness as the batting, but its clo value was 1.06 and it was excellent in heat retention. The results are shown in Table 1.

[0107] (Example 9) As the fancy yarn, two hollow fibers (40 T - 12 f, hollow ratio 30%) made of polyethylene terephthalate produced in Example 8 were combined and used.

[0108] Also, the core yarn, the holding yarn, and the fused yarn were made the same as in Example 8, and the moiré yarn was processed in the same manner as in Example 8, and a pressure steam treatment was performed to obtain a moiré yarn. The fineness of the obtained moiré yarn was 1758 dtex.

[0109] Using the moire yarn of Example 9, the ground yarn was made the same as in Example 1 and knitted on the same knitting machine as in Example 8. Regarding the fabric structure, in the wale direction of the fabric, the ground yarns were arranged at a ratio of 2 and the moire yarns were arranged at a ratio of 1, and knitting was performed in plain knitting with a fabric weight of 67 g / m 2 A fabric was obtained. Regarding this fabric, with the stitches formed by the ground yarn as a reference, three layers were stacked while shifting about half of the stitches in both the warp and weft directions, and the total fabric weight was 201 g / m 2 The resulting fabric was designated as the fabric of Example 9.

[0110] Regarding the fabric of Example 9, considering the ground yarns facing the wale direction of the fabric as warp yarns, the distance between the centers of the warp yarns was 1 mm (0.6 mm) and they overlapped, the thickness was 13 mm, and the transmission area ratio was 1%. Also, although the moire fancy yarns were caught in the stitches, since the stitches were small, the fancy yarns were dispersed in the voids.

[0111] The clo value of the zabuton made using the fabric of Example 9 was 1.70. It was a fabric with a large fabric weight and not very suitable as batting, but it had a small transmission area ratio and excellent heat retention. The results are shown in Table 1.

[0112] (Comparative Example 1) In Comparative Example 1, one piece of the fabric of Example 1 was used. The thickness of the fabric of Comparative Example 1 was 5 mm and the transmission area ratio was 55%. It was a fabric with a thin thickness and many voids.

[0113] The clo value of the zabuton made using the fabric of Comparative Example 1 was 0.43. It was a very lightweight fabric, but due to many voids, heat easily escaped and it was inferior in heat retention. The results are shown in Table 2.

[0114] (Comparative Example 2) In Comparative Example 2, one piece of the fabric of Example 4 was used. The thickness of the fabric of Comparative Example 2 was 7 mm and the transmission area ratio was 24%. It was a fabric with a thin thickness but few voids.

[0115] The clo value of the cushion made using the knitted fabric of Comparative Example 2 was 0.63. Since the thickness was thin, the amount of air retained was small and the heat retention property was insufficient. The results are shown in Table 2.

[0116] (Comparative Example 3) Using the knitted fabric of Example 1, they were overlapped so that the knitting stitches would not shift, and the total basis weight was 34 g / m 2 and this was used as the knitted fabric of Comparative Example 3. The thickness of the knitted fabric of Comparative Example 3 was 10 mm and the transmission area ratio was 51%. It was a knitted fabric with a large transmission area ratio and many voids.

[0117] The clo value of the cushion made using the knitted fabric of Comparative Example 2 was 0.54. Although it had an appropriate thickness, since there were many voids, heat easily escaped and it was inferior in heat retention property. The results are shown in Table 2.

[0118] (Comparative Example 4) Using the mohair yarn of Example 1, knitting was performed at 4G using a conventionally known circular knitting machine (manufactured by Koike Kikai Seisakusho Co., Ltd.) to obtain circular knitting. This circular knitting was cut open to make a single fabric with a basis weight of 196 g / m 2 and this was used as the knitted fabric of Comparative Example 4.

[0119] The thickness of the knitted fabric of Comparative Example 4 was 3 mm and the transmission area ratio was 13%. Compared with the raschel knitting of Example 1, the transmission area ratio became smaller. However, due to the large basis weight, the fabric was thin and had a hard touch, so it was not very suitable as batting. Also, the fancy yarn of the mohair yarn was caught in the knitting stitches, and the dispersion of the fancy yarn into the voids of the knitting stitches was less compared with the raschel knitting.

[0120] The clo value of the cushion made using the knitted fabric of Comparative Example 4 was 0.70. Since the thickness was thin, the heat retention property was insufficient. The results are shown in Table 2.

[0121]

Table 1

[0122]

Table 2

Explanation of Symbols

[0123] 1 Warp 2 Core yarn 3 Pressing yarn 4 Fusing yarn 5a, 5b, 5c, 5d Filling yarn 6 Mohair yarn 7a Edge length of knitted warp 7b Edge length of knitted weft 8 Protrusion length of warp 9 Yarn crossing position 10 Interval between fusing and fixing positions of warp

Claims

1. A knitted fabric containing mohair yarn, the knitted fabric having a thickness of 10 mm or more and a transmission area rate of 50% or less.

2. 2. The knitted fabric according to claim 1, wherein the knitted fabric is warp knitted.

3. 3. The knitted fabric according to claim 1, wherein the filament yarn of the mohair yarn contained in the knitted fabric is a hollow fiber.

4. A textile product comprising at least a part of the knitted fabric according to any one of claims 1 to 3.

5. A stuffing material at least partially using the knitted fabric according to any one of claims 1 to 3.

6. The stuffing described in claim 5, characterized in that the stuffing is made of two or more layers of knitted fabric containing the mohair yarn, and in the layered knitted fabrics, the average distance between the center points of the warp threads is 1 mm or more.

Images