Net-type stockings and producing method thereof

Abstract

To provide a technology for efficiently knitting net-type stockings and improving a run prevention function.SOLUTION: In a producing method of net-type stockings, low temperature thermofusible yarn is knitted during knitting, heat treatment is performed after knitting, low temperature thermofusible yarn is melted and a mesh is formed. The low temperature thermofusible yarn can be made of nylon with a low melting point of 100°C or less, preferably 80 to 95°C. High temperature thermofusible yarn having a melting point of 100°C or more, preferably 110°C to 120°C, may be used for a binding portion of a net fabric. As fabric yarn, covering yarn covering nylon yarn whose melting point exceeds 100°C with urethane yarn as core yarn may be used. The present invention also provides net-type stockings having the mesh formed by melting residues derived from knitting yarn and fusing it to fabric yarn. According to the net-type stocking technology of the present invention, the entire stocking including a mouth rubber part can continuously and integrally be knitted.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a net stocking and a method for manufacturing the same. [Background technology]

[0002] In recent years, there has been a growing need for a variety of patterns and decorations for stockings. In particular, net stockings with a net pattern are expected to see increased demand due to their decorativeness and the improved appearance of the legs (hereinafter, the pattern with multiple holes in a mesh pattern or the individual holes may also be referred to as net, mesh, lace, etc.). Known means for knitting net patterns include, for example, knitting lace using a raschel knitting machine or a sock knitting machine, and then forming openwork stitches and holes by transferring stitches.

[0003] Furthermore, when putting on or taking off stockings or washing them, they can get caught on something and cause runs (ladder-shaped scratches), and this problem is even more serious for stockings with holes that are prone to getting caught, such as those with a net pattern.As a countermeasure against runs, Patent Document 1 discloses a method of preventing runs by using a heat-fusible yarn to heat-fusiblely fuse the yarns in the knitted fabric at their intersections and fix the stitches. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5083561 Summary of the Invention [Problem to be solved by the invention]

[0005] Originally, Russell knitting machines were well-suited for knitting large quantities of standard patterned fabric at high speed, but they were not necessarily suited to flexibly knitting net patterns where the shape and size of the holes vary depending on the location on the fabric, or to flexibly inserting patterns into plain areas. Furthermore, with Russell knitting machines, the processes of cutting the finished fabric, sewing the toe area, and sewing the opening are all done by hand, making the process complicated.

[0006] In contrast, stocking knitting machines have the advantage of being able to flexibly knit a variety of different knitting patterns in small lots, being able to knit the entire stocking continuously and integrally from the cuff to the toe, and being able to use automatic machines to sew the toe and cuff, just like a Russell knitting machine. On the other hand, lace knitting on a hosiery machine generally results in a coarse gauge, and irregular movements of the knitting needles are involved when opening the mesh, resulting in slower speeds and poor knitting efficiency. In addition, since the mesh is already open in the knitted fabric, the fabric is less stable, making sewing and other processing difficult. Furthermore, when attempting to create a lace-knitted net pattern using a stocking knitting machine, the knitting needles at the locations where the mesh is to be opened rise, preventing the knitting yarn from being supplied and resulting in a complete detachment of the stitches, which causes the loops around the opened mesh to become unstable and easily come undone, leading to the problem that runs are more likely to occur when the fabric is pulled.In response to this, Patent Document 1 describes fixing the intersections of the knitted fabric with heat-sealing yarn to prevent runs, but does not specifically disclose any measures to prevent runs in mesh loops.

[0007] Therefore, an object of the present invention is to provide a technique for efficiently knitting net-type stockings and improving the anti-run function. [Means for solving the problem]

[0008] In order to solve the above problems, one of the representative methods for manufacturing net stockings of the present invention is to incorporate low-temperature heat-sealing yarn during knitting, and then heat-treat the net stockings after knitting to melt the low-temperature heat-sealing yarn and form a mesh. [Effects of the Invention]

[0009] According to the present invention, net stockings can be knitted efficiently and the anti-run function can be improved. Problems, configurations, and effects other than those described above will become apparent from the following description of the preferred embodiments. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram showing the stitch structure of stockings according to this embodiment before heat treatment. [Figure 2] FIG. 2 is a schematic diagram showing the stitch structure of the stockings of this embodiment after heat treatment. [Figure 3] FIG. 3 is a photographic image showing the state of the low-temperature thermal adhesive yarn before it is fused in the example. [Figure 4] FIG. 4 is a photographic image showing the state of the low-temperature heat-fusible yarn after fusion in the example. [Figure 5] FIG. 5 is a schematic diagram showing the net stockings of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Note that the present invention is not limited to this embodiment. In addition, in the description of the drawings, the same parts are designated by the same reference numerals.

[0012] In this embodiment, "stockings" is not limited by length and includes short stockings, long stockings, and clothing that covers the lower body such as pantyhose, as well as tights, socks, and hosiery. The knitting machine is not limited to a stocking knitting machine, but can also be applied to a circular knitting machine such as a sock knitting machine or other knitting machines.

[0013] Fig. 1 is a schematic diagram showing the stitch structure of stockings in this embodiment before heat treatment. A fabric (knitted fabric) is knitted with fabric yarn 10 (multiple types of fabric yarn 10 may be fed to form the knitted fabric), and further, a low-temperature heat-sealing yarn 20 (thin dotted line) having heat-sealing properties is fed and knitted in addition to the fabric yarn 10. The position at which the low-temperature heat-sealing yarn 20 is knitted in can be set as desired. The number of stitches into which the low-temperature heat-sealing yarn 20 is knitted can be set as desired, from 1 stitch to the number of cylinder needles, depending on the size of the hole, and can be set, for example, between 3 and 40 stitches.

[0014] Furthermore, if necessary, high-temperature heat-sealing yarn 30 (bold dotted line) having a higher melting point than the low-temperature heat-sealing yarn 20 can be partially knitted (or inserted) with cut bosses in areas where reinforcement is desired. In Figure 1, the circled X indicates an example in which high-temperature heat-sealing yarn 30 is knitted with cut bosses into the binding portion of the net fabric (the portion where the mesh intersects when a hole is made, also called the tab portion).

[0015] 2 is a schematic diagram showing the stitch structure of stockings in this embodiment after heat treatment. After knitting, heat treatment is applied in any appropriate process, whereby the melted low-temperature heat-sealing yarn 20 opens between adjacent binding portions, forming meshes (holes) (hereinafter, the outer periphery of the opened mesh is also referred to as a mesh loop. See, for example, the circled area Y). Mesh loops usually have a shape that bulges from the binding portion at the end toward the center. Furthermore, the melted material of the heat-treated low-temperature heat-sealing yarn 20 (hereinafter, what remains after melting the heat-sealing yarn is referred to as "melted residue") adheres to the fabric yarn 10 near the mesh loop (see, for example, the circled area Z). When the high-temperature heat-sealing yarn 30 is used, the portion where the melted residue of the high-temperature heat-sealing yarn 30 adheres is reinforced, forming a stronger net.

[0016] (Material of knitting yarn) The low-temperature heat-sealing yarn 20 is made of a low-melting nylon having a melting point of 100°C or less, and can melt to form holes. On the other hand, the high-temperature heat-sealing yarn 30 is made of a heat-sealing nylon having a melting point of more than 100°C, preferably 110°C to 120°C, higher than that of the low-temperature heat-sealing yarn 20. The material of the fabric yarn 10 can be a urethane core yarn and a nylon covering yarn. The covering yarn can be either a single covered yarn (SCY) or a double covered yarn (DCY). The fabric yarn 10 can also be a nylon yarn alone. The nylon used for the covering yarn and fabric yarn has a melting point above 100°C, and typically has a melting point of around 220°C.

[0017] (Manufacturing method) The manufacturing process for stockings generally consists of the steps of knitting, toe sewing, presetting, dyeing, and setting. Of these, the heat treatment for forming the mesh (holes) can be carried out in at least one of the steps of presetting, dyeing, and setting. The low-temperature heat-sealing yarn 20 may be melted and fixed in stages across multiple steps. For example, one method is to soften the low-temperature heat-sealing yarn 20 in the presetting step, and then the melted low-temperature heat-sealing yarn 20 adheres to the fabric yarn 10 in the dyeing step, and then the adhesion is strengthened in the setting step. The other steps are the same as the normal manufacturing process for stockings. When high-temperature heat-sealing yarn 30 is used, it is adjusted so that it is melted in the final setting process to reinforce the net.

[0018] (Actions and Effects) By manufacturing net-type stockings using the method of this embodiment, holes are created where the low-temperature heat-sealing yarn 20 melts, forming a mesh. In this case, the location and size of the holes can be adjusted by adjusting the knitting position and number of stitches (number of threads arranged in a wale) of the low-temperature heat-sealing yarn 20. It is also possible to feed the low-temperature heat-sealing yarn 20 from multiple yarn feeders and adjust the size of the holes by the number of threads arranged in a course. In any case, any desired net pattern can be efficiently designed depending on the knitting position and amount of the low-temperature heat-sealing yarn 20. Furthermore, the low-temperature heat-sealing yarn 20 melts and the molten residue adheres to the fabric yarn 10, making the mesh loops less likely to come undone and preventing wire breakage. The adhesive strength can be adjusted by increasing (or decreasing) the denier of the low-temperature heat-sealing yarn 20. Furthermore, since the knitting process can be completed without removing the stitches and forming holes, the surrounding loops are stabilized, preventing the occurrence of runs.Similarly, the stable loops before heat treatment make it easier to process, such as sewing.

[0019] Furthermore, when using high-temperature heat-sealing thread 30, the mesh binding section can be strengthened by partially weaving cut bosses into the binding section of the net fabric. It can also be used in other areas that require reinforcement. Furthermore, by using a high-temperature heat-sealing thread 30 made of a material with a high melting point and melting it in the final manufacturing process, it is possible to prevent the melted residue of the melted heat-sealing thread from firmly bonding fabrics together, which can cause problems in manufacturing. High-temperature fusion is also expected to improve the strength of the bond.

[0020] (Example) The net stockings of this embodiment are explained below using examples. In the knitting process, plain knitting was performed using fabric yarn 10, low-temperature heat-sealing yarn 20 was knitted into 15 stitches, and high-temperature heat-sealing yarn 30 was inserted into the binding part of the net fabric using cut bosses. The composition conditions are as follows: Knitting machine: Lonati LA02MJ 400N Threads used: Fabric thread 10: SCY30 / 12-5, 70-68WN, 30 / 100-96SCY Low-temperature heat-sealing thread 20: Elder (registered trademark) High-temperature heat-sealing thread 30: Joyner (registered trademark) The fusion process in the knitting process is as follows. Presetting: Presetting was performed at 95°C. The low-temperature heat-fusible thread 20 began to soften and melt at around 80°C. Dyeing: Dyeing was carried out at 95° C. The low-temperature heat-fusible yarn 20 melted, and the molten residue of the synthetic resin adhered to the gaps between the fabric yarns 10. Setting: Setting was performed at 110° C. The high-temperature heat-fusible thread 30 began to melt at temperatures above 100° C., and the molten residue of the synthetic resin adhering to the fabric thread 10 solidified firmly and became difficult to unravel.

[0021] Figure 3 is a photograph showing the state of the low-temperature heat-sealing yarn before it is fused in the example. Figure 3(a) is an image taken under natural light of the state in which the low-temperature heat-sealing yarn 20 is knitted into the fabric yarn 10 of the example. Figure 3(b) is an enlarged image taken under the same photographic environment of a knitted fabric using fabric yarn 10 (20d black Pu / 40-36 black Ny) made of black dope-dyed covering yarn and thick low-temperature heat-sealing yarn 20 (70d elder) to make it easier to see the state around the mesh loops before and after heat treatment (the fabric yarn 10 appears blackish, and the low-temperature heat-sealing yarn 20 appears whitish). Figure 4 is a photograph showing the state of the low-temperature thermal adhesive yarn after fusion in the example. Figures 4(a) and (b) were taken under the same conditions as Figures 3(a) and (b), respectively. As shown in Figure 4(a), openings are formed in the mesh after heat treatment. Also, as can be seen in Figure 4(b), it can be seen that the melted residue of the synthetic resin derived from the low-temperature heat-sealing yarn 20 adheres to the fabric yarn 10 near the mesh loops (see, for example, the area circled by the dotted line).

[0022] FIG. 5 is a schematic diagram showing net-type stockings of an example. FIG. 5(a) is a front view, and FIG. 5(b) is a side view. A net region 40 in which mesh is formed using the manufacturing method of this embodiment is mixed with a plain knit region (hereinafter referred to as the "plain knit region") 50 (see the region painted in black). As mentioned above, the size of the mesh in the net region 40 can be adjusted and can also be varied depending on the location. The pattern can also be designed appropriately, taking aesthetic appeal into consideration. Stockings in which the net region 40 and the plain knit region 50 are knitted continuously and intermixed as in this embodiment are difficult to produce using a Russell knitting machine or the like, but are only possible with the manufacturing method of this embodiment. Similarly, the cuff elastic portion 60 can be knitted continuously and integrally with the other regions.

[0023] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the gist of the present invention. For example, the technical concept of forming a mesh using a heat-fusible yarn of the present invention and preventing wire run-in is not limited to stockings, but can also be applied when knitting net patterns on shirts, gloves, and other general clothing.

[0024] The following are examples of possible embodiments of the present invention, but the present invention is not limited to these. (Aspect 1) A method for manufacturing net stockings, comprising knitting low-temperature heat-sealing yarn during knitting, and then heat-treating the knitted stockings after knitting to melt the low-temperature heat-sealing yarn and form a mesh. (Aspect 2) The method for producing net stockings according to aspect 1, wherein the low-temperature heat-fusible yarn is made of nylon having a melting point of 100°C or less, preferably 80 to 95°C. (Aspect 3) The method for producing net stockings according to aspect 1 or 2, wherein high-temperature heat-sealing yarn having a melting point exceeding 100°C, preferably 110°C to 120°C, is used for the binding portion of the net fabric. (Aspect 4) A method for producing net stockings according to any one of aspects 1 to 3, wherein the fabric yarn is a covered yarn obtained by covering a nylon yarn having a melting point exceeding 100°C with a urethane yarn as a core yarn. (Aspect 5) The method for producing net stockings according to any one of aspects 1 to 4, wherein the heat treatment is carried out in at least one of the steps of presetting, dyeing, and setting. (Aspect 6) The method for producing net stockings according to any one of aspects 1 to 5, wherein the size of the holes in the mesh is adjusted by adjusting the number of stitches in a predetermined course of the low-temperature heat-fusible yarn. (Aspect 7) The method for producing net stockings according to any one of aspects 1 to 6, wherein the size of the holes in the mesh is adjusted by adjusting the number of low-temperature heat-fusible yarns arranged in a course. (Aspect 8) The net stockings have a mesh formed by melted residue derived from knitting yarn fused to fabric yarn. (Aspect 9) The net stockings according to aspect 8, wherein the entire stocking, including the cuff elastic, is knitted continuously and integrally. (Aspect 10) The net stocking according to aspect 8 or 9, wherein the net region having the mesh formed therein and a plain knit region are mixed. (Aspect 11) The net stockings according to any one of aspects 8 to 10, wherein the knitting yarn is a low-temperature heat-bonding yarn. (Aspect 12) 12. The net stocking according to claim 11, wherein the low-temperature heat-fusible yarn is nylon having a melting point of 100°C or less, preferably 80 to 95°C. [Explanation of symbols]

[0025] 10...Fabric thread, 20...Low temperature heat fusion thread, 30...High temperature heat fusion thread, 40...Net area, 50...Plain knitting area, 60...Cuff elastic part

Claims

1. A method for manufacturing net stockings, comprising knitting low-temperature heat-sealing yarn during knitting, and then heat-treating the knitted stockings after knitting to melt the low-temperature heat-sealing yarn and form a mesh.

2. 2. The method for manufacturing net stockings according to claim 1, wherein the low-temperature heat-fusible yarn is made of nylon having a melting point of 100°C or less, preferably 80 to 95°C.

3. The method for manufacturing net stockings according to claim 1 or 2, wherein high-temperature heat-sealing yarn having a melting point exceeding 100°C, preferably 110°C to 120°C, is used for the binding portion of the net fabric.

4. 3. The method for manufacturing net stockings according to claim 1 or 2, wherein the fabric yarn is a covered yarn obtained by covering a nylon yarn having a melting point exceeding 100°C with a urethane yarn as a core yarn.

5. The method for producing net stockings according to claim 1 or 2, wherein the heat treatment is carried out in at least one of the steps of presetting, dyeing, and setting.

6. 3. The method for manufacturing net stockings according to claim 1, wherein the size of the holes in the mesh is adjusted by adjusting the number of stitches in a predetermined course of the low-temperature heat-fusible yarn.

7. The method for manufacturing net stockings according to claim 1 or 2, wherein the size of the mesh holes is adjusted by adjusting the number of low-temperature heat-fusible yarns arranged in a course.

8. The net stockings have a mesh formed by melted residue derived from knitting yarn fused to fabric yarn.

9. 9. The net stocking according to claim 8, wherein the entire stocking including the cuff is knitted continuously and integrally.

10. The net stocking according to claim 8, wherein the net region where the mesh is formed and the plain knit region are mixed.

11. The net stockings according to any one of claims 8 to 10, wherein the knitting yarn is a low-temperature heat-sealing yarn.

12. The net stocking according to claim 11, wherein the low-temperature heat-fusible yarn is a low-melting nylon having a melting point of 100°C or less, preferably 80 to 95°C.

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