Quilting knitted fabric and bed pad including the same

Abstract

To provide a quilting knitted fabric and a bed pad, which are excellent in productivity and have slip-proof property.SOLUTION: A quilting knitted fabric is a knitted fabric, which has a front surface texture, a rear surface texture, and an insertion yarn between the front surface texture and the rear surface texture and is formed by connecting the front surface texture and the rear surface texture. The insertion yarn is bulky textured yarn. The rear surface texture has a knitting yarn constituted solely of polyurethane fibers. A bed pad includes the quilting knitted fabric.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to quilting fabric.

Background Art

[0002] Conventionally, for the purpose of comfort during sleep, a cushioned quilting pad is often used on a bed mat or futon. Also, such pads are required to have anti-slip properties because the position of the pad moves on the bed mat or futon as the user's body moves during sleep, making it uncomfortable to sleep. Generally, there is a method of attaching rubber to the four corners of the pad and hooking the rubber on the bed mat or futon to integrate them and suppress slipping. Alternatively, since the method using rubber is time-consuming, as a solution, products with dot-shaped anti-slip resin provided on the back surface of the pad have also been widely developed (Patent Document 1).

[0003] Alternatively, fabrics that serve as anti-slip materials are also being developed. When using such materials, four materials, namely, a surface fabric, batting, a back fabric, and an anti-slip material, are prepared, made into four layers, and then sewn and integrated to form an anti-slip quilting material (Patent Document 2).

[0004] On the other hand, as for the quilting material itself, it is possible to manufacture it using a circular knitting machine or a loom by using inserted yarns as batting and making a quilting knitted fabric in which the front knitted fabric and the back knitted fabric are partially connected. In that case, the preparation of three materials and the sewing process are not required, but it is necessary to impart anti-slip properties. As described above, a method of attaching rubber to the four corners or providing dot-shaped resin after manufacturing the quilting material is adopted (Patent Document 3).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in order to manufacture such materials, as described above, it is necessary to prepare a plurality of materials such as the face fabric, the batting, and the back fabric, or to perform steps such as resin installation, and the productivity is extremely poor.

[0007] Therefore, an object of the present invention is to provide a quilting fabric and a laying pad having excellent productivity and anti-slip properties.

Means for Solving the Problems

[0008] In order to obtain a quilting fabric having excellent productivity and anti-slip properties, it has been found that the problem can be solved by having a portion in the back fabric portion composed of polyurethane fibers alone, and the present invention has been reached. That is, the present invention has the following configurations. (1) A fabric comprising a face fabric portion, a back fabric portion, and an inserted yarn between the face fabric portion and the back fabric portion, connecting the face fabric portion and the back fabric portion, wherein the inserted yarn is a bulky processed yarn, and the back fabric portion has a knitting yarn composed of polyurethane fibers alone. A quilting fabric. (2) The quilting fabric according to (1), wherein the mixing ratio of the polyurethane fibers in the back fabric portion is 30% by mass or more and 90% by mass or less with respect to 100% by mass of the back fabric portion. (3) The quilting fabric according to (1) or (2), wherein the inserted yarn is a bulky processed yarn having a residual torque of 30 t / m or less. (4) The quilting fabric according to any one of (1) to (3), wherein the back fabric portion has a portion formed by loops of only polyurethane fibers. (5) The quilting fabric according to any one of (1) to (4), which is a quilting fabric base fabric connecting the face fabric portion and the back fabric portion with polyurethane fibers. (6) A laying pad including the quilting fabric according to any one of (1) to (5). [Effect of the Invention]

[0009] According to the present invention, a quilting fabric and a laying pad having excellent productivity and anti-slip properties can be obtained. [Embodiments for Carrying Out the Invention]

[0010] The quilting fabric of the present invention includes a face fabric tissue part, a back fabric tissue part, and an inserted yarn between the face fabric tissue part and the back fabric tissue part, and is a fabric that connects the face fabric tissue part and the back fabric tissue part. It is important that the inserted yarn is a bulky processed yarn and that there is a part in the back fabric tissue part that is composed of polyurethane fibers alone. Note that the front and back of the above-mentioned face fabric tissue part and back fabric tissue part mean the relative relationship between one side of the quilting fabric and the opposite side. Note that during use, the face fabric side is often used on the side that is easily visible.

[0011] By using a bulky processed yarn as the inserted yarn, the swelling required for the quilting material can be obtained.

[0012] Furthermore, since there is a part in the back fabric tissue part that is composed of polyurethane fibers alone, the polyurethane is easily arranged in the outermost layer part of the fabric and is likely to be exposed, and excellent anti-slip properties can be obtained.

[0013] [Face Fabric Tissue Part] Any yarn can be used for the surface fabric part of the quilting fabric of the present invention. It may be long fiber, short fiber, synthetic fiber, or natural fiber. It may be 100% of a specific fiber or a cross-weave of a specific fiber and other fibers. It can be selected according to the characteristics required for the product. For example, when it is desired to obtain contact cold sensitivity, it is preferable to use long fibers of nylon or polyethylene. When it is desired to obtain moisture absorption and water absorption properties, it is preferable to select spun yarns containing cotton or rayon. It is also possible to use 100% rayon spun yarn. When using 100% rayon spun yarn results in insufficient shape retention and stiffness, it is possible to use a blended yarn of rayon and polyester or to cross-weave rayon spun yarn and polyester spun yarn.

[0014] The thickness of the yarn is arbitrary and can be appropriately selected according to the application. However, when used as a laying pad, in the case of spun yarn, it is preferable to use yarns from 50 to 10 count, and in the case of long fiber, it is preferable to use yarns from 56 dtex to 330 dtex.

[0015] [Lining fabric part] The lining fabric part has a portion composed of polyurethane fiber alone. It is preferably not aligned or covered with other yarns. The lining fabric part has a knitted yarn composed of polyurethane fiber alone, but other yarns other than the knitted yarn composed of polyurethane fiber alone may be used in combination and cross-woven.

[0016] The yarn cross-woven with the polyurethane fiber in the above-mentioned lining fabric part can also be arbitrarily selected in the same manner as the yarn of the surface fabric part. When there are no special required characteristics, using polyester long fiber is easy to obtain and inexpensive. Furthermore, using a false-twist processed yarn or a raw yarn improves the anti-permeability of the lining fabric, makes the inserted yarn less visible from the back, and is preferable in terms of appearance. In this case, the thickness of the yarn cross-woven with the polyurethane fiber is arbitrary, but it is preferable to use yarns from 56 dtex to 330 dtex. If it is thinner than 56 dtex, the inserted yarn can be seen through from the back of the quilting fabric, resulting in a poor appearance. If it is too thick, the polyurethane fiber is less likely to be exposed on the outer layer, and the anti-slip property is inferior.

[0017] Here, the mixing ratio of the polyurethane fiber used in the lining fabric part is desirably 30% by mass or more and 90% by mass or less with respect to 100% by mass of the lining fabric part. When the mixing ratio of the polyurethane fiber is 30% by mass or more, the amount of the polyurethane fiber arranged and exposed in the outermost layer part of the fabric becomes sufficiently large, and sufficient anti-slip property can be obtained. Conversely, when the mixing ratio of the polyurethane fiber is 90% by mass or less, the shrinkage force of the lining fabric part is moderately suppressed, and the shape retention property of the entire fabric becomes good. Furthermore, the transparency of the lining fabric part is also suppressed, the inserted yarn inside the fabric is difficult to see from the lining fabric part side, and the appearance is also good. More desirably, the mixing ratio of the polyurethane fiber used in the lining fabric part is 50% by mass or more and 80% by mass or less, and anti-slip property, shape retention property, and good appearance can be easily obtained.

[0018] There is no particular limitation on the polyurethane fiber used for the lining fabric part. For example, among commercially available products, there is the polyurethane elastic fiber Lycra fiber manufactured by Toray · Operontex Co., Ltd. Here, the fineness of the polyurethane fiber is preferably 77 dtex or more and 330 dtex or less. When it is 77 dtex or more, the inserted yarn is difficult to see through from the back surface of the quilting fabric, the strength is sufficient, and the yarn is not easily broken during use, and the effect as an anti-slip agent is sufficiently obtained, which is preferable. Also, when it is 330 dtex or less, the shrinkage force as a knitted fabric does not become too strong, and it becomes easy to maintain the shape. More preferably, it is 111 dtex or more and 278 dtex or less.

[0019] Also, the knitting structure of the lining fabric part is not particularly limited, but it is desirable that the polyurethane fiber is arranged in the outermost layer part of the fabric to such an extent that sufficient anti-slip property can be obtained.

[0020] In the lining fabric part, the knitting yarn composed only of polyurethane fibers means a yarn in which polyurethane fibers are not aligned or covered with other yarns and are composed alone. Among them, it is preferable that the lining fabric part has a portion where loops are formed only by polyurethane fibers. Here, "having a portion where loops are formed only by polyurethane fibers" means having a portion where loops are formed by knitting only with polyurethane fibers.

[0021] When knitting polyurethane fibers in circular knitting, it is generally common to knit them in alignment with the ground yarn forming the fabric body by a plating method or the like. Alternatively, a yarn in which polyurethane fibers are covered with the ground yarn forming the fabric body is used. However, in such a structure, since the polyurethane fibers are always present on the same knitting stitch as the ground yarn, the polyurethane fibers are covered by the ground yarn, and it is extremely difficult to arrange the polyurethane fibers in the outermost layer part of the lining fabric part. In the present invention, by knitting the lining fabric part using a knitting yarn composed only of polyurethane fibers, the used polyurethane fibers can be efficiently exposed in the outermost layer part of the lining fabric part.

[0022] A method of creating a portion composed only of polyurethane fibers can also adopt a multi-layer structure fabric in which the polyurethane fibers connect one needle loop and another needle loop located in another course on the sinker surface. However, if the fabric has a portion where loops are formed only by polyurethane fibers, a single-layer fabric is formed in the lining fabric part where only polyurethane fibers exist, and there is nothing covering the polyurethane fibers, making it easier to obtain the aforementioned structure.

[0023] [Inserted yarn] The quilting knitted fabric of the present invention includes an inserted yarn between the above-mentioned surface fabric part and the above-mentioned lining fabric part.

[0024] The bulky textured yarn used as the inserting yarn is not particularly limited, but false-twisted yarn, crimped yarn with a side-by-side cross-section, air-mixed fiber yarn, composite yarn, etc. are preferred. In order to obtain a large swelling in the fabric, a false-twisted yarn with strong crimp and thick fineness is used. In order to suppress the swelling, a false-twisted yarn with fine crimp and fine fineness is used, or a composite yarn in which thick and fine fineness yarns are air-mixed and compounded, maintaining the shape retention with the thick fineness yarn and giving a soft texture with the fine fineness yarn. The bulky textured yarn can be selected according to the swelling and texture required for the fabric.

[0025] As the material, it is preferable to use polyester fiber with a crisp feeling to easily obtain bulkiness. However, nylon fiber can also be used if a soft texture is desired. Also, it is possible to use hollow cross-section fibers to obtain a lightweight feeling.

[0026] It is preferable to use a bulky textured yarn with a residual torque of 30 t / m or less for these bulky textured yarns. By using a processed yarn with a low residual torque, the yarn is less likely to be twisted by torque. As a result, the inserting yarn is less likely to be biased between the surface fabric part and the back fabric part, and the quilting shape is likely to be uniform, which is preferable in terms of appearance. More preferably, the residual torque is 10 t / m or less. Since polyurethane fiber is used in the back fabric part, the fabric after knitting and weaving has a certain shrinkage. By using a yarn with a small residual torque, the twisting of the yarn that is likely to occur during this shrinkage is suppressed. Therefore, the smaller the residual torque, the easier it is to stabilize the shape. The lower limit is preferably a residual torque of 0 t / m.

[0027] [Quilting fabric] The quilting fabric of the present invention includes a surface fabric part, a back fabric part, and an inserted yarn between these two fabric parts as described above, and is a quilting fabric in which the surface fabric part and the back fabric part are joined. A quilting fabric usually has a joined part where the surface fabric part and the back fabric part are joined and other parts. By joining the surface fabric part and the back fabric part at the joined part, the other parts are lifted up, and it becomes possible to form a pattern. The joined part can usually be provided continuously or intermittently so that the other parts are divided into a plurality of parts. The mode of division may be not only a mode in which the other parts are simply divided, but also a mode in which the divided other parts are surrounded by a continuous joined part, or as a result of being incompletely surrounded, adjacent other parts may be partially connected.

[0028] In order to partially join the surface fabric part and the back fabric part, the two fabric parts may be partially joined using a knitting yarn that constitutes the surface fabric part or the back fabric part, or a joining yarn different from these knitting yarns, and there is no particular limitation. At that time, by inserting an inserted yarn between the two fabric parts, an inserted yarn can be provided between the two fabric parts.

[0029] The joining yarn, which is a yarn for joining the surface fabric part and the back fabric part, is preferably a polyurethane fiber.

[0030] Since the quilting knitted fabric of the present invention contains polyurethane fibers in the lining fabric part, the whole fabric is likely to shrink after knitting on a circular knitting machine. At this time, the lining fabric part maintains a flat structure due to the shrinkage of the polyurethane fibers, the inserted yarn forms a bulge because it is a bulky processed yarn, and the surface fabric part loosens as a fabric between the connecting parts. In particular, since the part other than the connecting part in the surface fabric part usually does not contain polyurethane fibers, it loosens more as a fabric, so that a quilting knitted fabric with a bulge as a whole and an excellent appearance can be obtained. In particular, in a material in which the mixing ratio of the polyurethane fibers in the lining fabric part is designed to be high in order to improve the anti-slip property, the above shrinkage is likely to increase, and the yarn at the connecting part is also likely to loosen, so it is difficult to manufacture so as to maintain a sharp quilting shape. However, if polyurethane fibers are used for the connecting yarn, the loosening of the yarn at the connecting part can be suppressed, and the manufacturing can be facilitated.

[0031] [Method for manufacturing a quilting knitted fabric] The manufacturing method of the quilting knitted fabric of the present invention is not particularly limited. For example, it is possible to manufacture by attaching a pipe yarn carrier for inserting an inserted yarn between the surface fabric part and the lining fabric part, and a yarn feeding device for polyurethane fibers to a normal double-knit circular knitting machine. It is also possible to use normal commercially available products for the pipe yarn carrier and the yarn feeding device for polyurethane fibers. Feed each yarn according to the arrangement of the polyurethane fibers and the yarn that is knitted together with them to form the lining fabric part. For example, in the case of a 1:1 arrangement, the polyurethane fiber and the other yarn are fed alternately. In the case of a 1:2 arrangement, one polyurethane fiber is fed first, and then two of the other yarns are fed, and this is repeated.

[0032] The surface fabric part is not particularly limited, but cotton fabric is preferable in terms of the smoothness of the surface when used as a laying pad, the strength of the fabric, and the ease of manufacturing. The lining fabric part is not particularly limited either, but cotton fabric is preferable in terms of the strength of the fabric and the ease of manufacturing.

[0033] As described above, the surface fabric part and the back fabric part are partially joined, but the joining position is not particularly limited, and generally, a square joined in the vertical and horizontal directions or a diamond-shaped quilting pattern joined in the bias direction is preferably used. The size of the quilting pattern is not particularly limited, but from the viewpoint of a size that gives particularly good swelling and stiffness to the fabric, a size of 5 cm square or less is preferable. Also, as the lower limit, a size of 1 cm square or more is preferable.

[0034] As a means of joining, a method of knitting the knitting yarns constituting the back fabric part so as to partially constitute a part of the surface fabric part is generally used. At the knitted part, the surface fabric part and the back fabric part are integrated, that is, joined. Since this joining position can be arbitrarily set, the above-mentioned square or diamond patterns can be created.

[0035] Thus, the quilting knitted fabric of the present invention obtained has an appearance such as appropriate swelling and stiffness, and excellent anti-slip properties, and thus can be suitably used for a floor mat.

Example

[0036] Next, the present invention will be specifically described with reference to examples, but the present invention is not limited to these examples at all.

[0037] (Mixing ratio) From the product of the present invention, the back fabric part was cut off with scissors so as not to include the joined part, and measured by a dissolution method based on JIS L1030-2:2012.

[0038] (Residual torque) Measured based on JIS L1095:2010 9.17 Snarl index B method.

[0039] (Number of entanglements) Measured based on JIS Ll013:2010 8.15 Degree of entanglement. <�

[0040] (Example 1) Using a 20G 38-inch (96.52 cm) electronic dobby double circular knitting machine, a basket weave was knitted only with 20-count rayon spun yarn for the face fabric tissue part, and a basket weave with a 1:1 arrangement of 156 dtex - 10f polyurethane fiber and 167 dtex - 48f polyester (polyethylene terephthalate) filament yarn was knitted for the back fabric tissue part. A quilting knit was produced and knitted by connecting the face fabric tissue part and the back fabric tissue part with the polyurethane fiber so as to form a square quilt of 5 cm in the well direction × 5 cm in the course direction. At this time, as the inserted yarn, a polyester yarn (polyethylene terephthalate yarn) with 60 twists per meter was used, which was a 1-heater false-twisted yarn of 1333 dtex - 288f with a residual torque of 25 t / m. Also, the mixing ratio of the polyurethane fiber in the back fabric tissue part was 72% by mass with respect to 100% by mass of the back fabric tissue part, and the polyurethane fiber formed loops only with the polyurethane fiber in the back fabric tissue part, and thus had a portion arranged in the outermost layer part of the fabric.

[0041] When this quilting knit was used as a laying pad on a bed mat covered with a 100% cotton fabric with a basis weight of 250 g / m 2 , the laying pad did not shift even during sleep, and as a result, sufficient anti-slip property was obtained. Also, it was a quilting knit with a swollen appearance and a stable shape without loosening at the connecting part.

[0042] (Example 2) The quilting knit was produced and knitted under the same conditions as in Example 1, except that the face fabric part was knitted with only 20s cotton spun yarn to form a twill weave, and the back fabric part was a twill weave with a 1:2 arrangement of 156 dtex - 10f polyurethane fiber and 167 dtex - 48f polyester filament yarn. The 1:2 arrangement means that after knitting in one polyurethane fiber, two polyester (polyethylene terephthalate) filament yarns are continuously knitted in, and this cycle of three yarns is repeated. At this time, the mixing ratio of the polyurethane fiber in the back fabric part was 56% by mass based on 100% by mass of the back fabric part, and the polyurethane fiber formed loops only with the polyurethane fiber in the back fabric part, and had a position arranged in the outermost layer part of the fabric.

[0043] When this quilting knit was used as a laying pad on the same bed mat as in Example 1, the laying pad did not shift during sleep, and a sufficient anti-slip property was obtained. Also, due to the lower mixing ratio of the polyurethane fiber than in Example 1, the shrinkage of the fabric was smaller, and it had less swelling than the quilting knit of Example 1, and was in a flat shape, but it was a quilting knit with a stable shape without looseness at the joining part.

[0044] (Comparative Example 1) The quilting knit was produced and knitted under the same conditions as in Example 1, except that the back fabric part was arranged with 78 dtex - 5f polyurethane fiber and 83 dtex - 36f polyester filament yarn by plating. At this time, the mixing ratio of the polyurethane fiber in the back fabric part was 72% by mass based on 100% by mass of the back fabric part, and since the polyurethane fiber was knitted in alignment with the polyester filament yarn, the polyurethane fiber was buried in the polyester filament yarn, and it was difficult to visually recognize the polyurethane fiber in the outermost layer part of the fabric.

[0045] When this quilting knit was used as a laying pad on the same bed mat as in Example 1, the laying pad shifted during sleep, which was uncomfortable, and the result was insufficient anti-slip property.

[0046] (Comparative Example 2) A quilting knit was produced and knitted under the same conditions as in Example 2, except that a covering yarn in which 78 dtex - 5f polyurethane fiber was covered with 167 dtex - 48f polyester filament yarn was used as the lining fabric part. At this time, the mixing ratio of the polyurethane fiber in the lining fabric part was 13% by mass with respect to 100% by mass of the lining fabric part. Since the polyurethane fiber was covered with polyester filament yarn, the polyester filament yarn was arranged outside the covering yarn, and it was difficult to visually recognize the polyurethane fiber in the outermost layer part of the fabric.

[0047] When this quilting knit was used as a laying pad on the bed mat, the laying pad shifted during sleep, which was uncomfortable and was a result of insufficient anti-slip property.

[0048] (Comparative Example 3) A quilting knit was produced and knitted under the same conditions as in Example 1, except that 667 dtex - 144f polyester raw yarn (polyethylene terephthalate raw yarn) was used as the inserted yarn. The inserted yarn swelled in the knitted fabric, had no voids compared to Example 1, and became a flat and poorly shaped quilting knit.

Industrial Applicability

[0049] According to the present invention, it is possible to provide a quilting fabric having excellent productivity and anti-slip property.

Claims

1. A knitted fabric comprising a face fabric part, a back fabric part, and an inserted yarn between the face fabric part and the back fabric part, the face fabric part and the back fabric part being joined together, wherein the inserted yarn is a bulked yarn, and the back fabric part is a quilting knitted fabric having a knitting yarn composed of polyurethane fibers alone.

2. The quilting knitted fabric according to Claim 1, wherein the mixing ratio of polyurethane fibers in the back fabric part is 30% by mass or more and 90% by mass or less with respect to 100% by mass of the back fabric part.

3. The quilting knitted fabric according to Claim 1 or 2, wherein the inserted yarn is a bulked yarn having a residual torque of 30 t / m or less.

4. The quilting knitted fabric according to Claim 1 or 2, wherein the back fabric part has a portion where loops are formed only of polyurethane fibers.

5. The quilting knitted fabric according to Claim 1 or 2, which is a quilting knitted base fabric in which the face fabric part and the back fabric part are joined together with polyurethane fibers.

6. A laying pad comprising the quilting knitted fabric according to Claim 1 or 2.