3D woven floor

Abstract

To provide a lightweight, three-dimensional warp-knitted fabric that offers cushioning and flexibility when folded, similar to soft polyurethane foam. [Solution] The three-dimensional warp knitted fabric according to this embodiment is a three-dimensional warp knitted fabric knitted with a three-reed. The three-dimensional warp knitted fabric consists of a face fabric structure, a backing fabric structure, and a connecting structure that connects the face fabric structure and the backing fabric structure. The connecting yarn constituting the connecting structure is a multifilament crimped yarn with a total fineness of 80 to 170 dtex and a single fiber fineness of 2 to 5 dtex. The connecting structure is a diagonal connecting structure or a truss connecting structure. The weight of the three-dimensional warp knitted fabric is 550 g / m 2 The following applies:

Description

[Technical Field]

[0001] This invention relates to a three-dimensional warp-knitted fabric. More specifically, it relates to a three-dimensional warp-knitted fabric that can be used as a cushioning material in place of a soft polyurethane foam sheet. [Background technology]

[0002] Surface materials used in vehicle interiors and other interior furnishings are sometimes used as composite surface materials with a cushioning material laminated on the back. Traditionally, flexible polyurethane foam was the mainstream cushioning material. However, flexible polyurethane foam had various problems, such as environmental impact and difficulty in recycling. Therefore, three-dimensional knitted fabrics and other materials have come to be used as alternative cushioning materials to flexible polyurethane foam.

[0003] For example, Patent Document 1 describes a three-dimensional three-dimensional sheet made of a three-dimensional knitted fabric in which a front knit and a back knit are connected by connecting yarns. This three-dimensional knitted fabric is described in which at least the front knit is knitted in a perforated structure, the connecting yarn is made of monofilament yarn, at least the front knit is knitted with two or more ground knitting yarns and one or more binding yarns, at least part or all of the stitches of the front knit are made of one or more ground knitting yarns and one or more binding yarns, the connecting yarn is tightened to the ground knitting yarn by the binding yarn, and the total thickness of the yarns constituting the stitches in both the front and back knits is set to 500 denier or more. It is described that this makes it possible to provide a three-dimensional three-dimensional sheet that has good cushioning properties, is lightweight, durable, breathable, has good pressure distribution, vibration absorption, shape stability and slip resistance, is firm and does not feel like it is bottoming out, and has a good feel and texture.

[0004] Patent Document 2 describes a three-dimensional knitted fabric for cushioning material having two layers of knitted fabric on the front and back and a monofilament connecting yarn connecting the two layers of knitted fabric, wherein the knitted fabric and the connecting yarn are made of biodegradable fibers. It is stated that this makes it possible to provide a three-dimensional knitted fabric for cushioning material that is biodegradable, has a moderate elasticity suitable for use as a cushioning material, and has excellent cushioning properties that recover well after repeated compression in the thickness direction. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2001-234456 [Patent Document 2] Japanese Patent Publication No. 2005-179842 [Overview of the project] [Problems that the invention aims to solve]

[0006] In the three-dimensional 3D sheet described in Patent Document 1, although the surface knit is knitted in a perforated structure, it is lightweight and has excellent cushioning properties because monofilament yarn is used for the connecting yarn, but when the cushioning material is bent, unnatural creases occur and it lacks flexibility. In the three-dimensional knitted fabric for cushioning material described in Patent Document 2, although the connecting yarn is monofilament yarn, it is cushioning properties, but when the cushioning material is bent, unnatural creases occur and it lacks flexibility.

[0007] This invention has been made in view of the current situation, and its purpose is to provide a three-dimensional warp-knitted fabric that is lightweight and has cushioning properties and flexibility when folded similar to those of soft polyurethane foam.

[0008] The present invention includes embodiments shown below. [1] A three-ply warp knitted fabric, wherein the three-ply warp knitted fabric comprises a face fabric structure, a backing fabric structure, and a connecting structure that connects the face fabric structure and the backing fabric structure, wherein the connecting yarn constituting the connecting structure is a multifilament crimped yarn with a total fineness of 80 to 170 dtex and a single fiber fineness of 2 to 5 dtex, the connecting structure is a diagonal connecting structure or a truss connecting structure, and the basis weight is 550 g / m 2 The following is a three-dimensional warp-knitted fabric. A composite surface material in which a surface material is laminated onto the three-dimensional warp-knitted fabric of [2][1]. [Effects of the Invention]

[0009] According to embodiments of the present invention, it is possible to provide a three-dimensional warp-knitted fabric that is lightweight and has cushioning properties and flexibility when folded similar to those of soft polyurethane foam. [Brief explanation of the drawing]

[0010] [Figure 1] A cross-section of a three-dimensional warp-knitted fabric, viewed from the end of the knitting process. [Modes for carrying out the invention]

[0011] The three-dimensional warp-knitted fabric according to this embodiment is a three-dimensional warp-knitted fabric knitted with a three-reed, and consists of a face fabric structure, a backing fabric structure, and a connecting structure that links the face fabric structure and the backing fabric structure. Because it is knitted with a three-reed, the total amount of yarn used can be reduced, and a lightweight three-dimensional warp-knitted fabric can be obtained. In addition, because it has a connecting structure, gaps are formed by the connecting yarn, resulting in excellent cushioning properties. In this embodiment, "face fabric structure" refers to the knitted fabric structure that is bonded to the surface material when it is used as a composite surface material by bonding it to the surface material.

[0012] The fiber material of the yarn used for the ground yarns forming the surface fabric structure and the back fabric structure is not particularly limited, and examples thereof include conventionally known fibers such as natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers, and two or more of these may be combined. Among them, synthetic fibers are preferable from the viewpoint of durability, and it is preferable to use polyester fibers or fibers made of the same material as the material used for the skin material from the viewpoint of recyclability.

[0013] The form of the yarn used for the ground yarns forming the surface fabric structure and the back fabric structure is not particularly limited, and examples thereof include yarns in conventionally known forms such as spun yarns, multifilament yarns, and monofilament yarns. Among them, from the viewpoint of flexibility during bending, it is preferable to use a multifilament yarn, and from the viewpoints of flexibility during bending, cushioning properties, and touch, a multifilament crimped yarn is more preferable.

[0014] The fineness (total fineness) of the yarn used for the ground yarns forming the surface fabric structure and the back fabric structure is not particularly limited, and it is preferably 80 to 170 dtex, more preferably 80 to 110 dtex. When the total fineness of the ground yarn is within this range, the three-dimensional warp knitted fabric has firmness and is likely to obtain flexibility during bending. When the total fineness of the ground yarn is below the upper limit value, a lightweight three-dimensional warp knitted fabric can be obtained.

[0015] The fineness (single fiber fineness) of the fiber used for the ground yarns forming the surface fabric structure and the back fabric structure is not particularly limited, and it is preferably 2 to 4.5 dtex. When the single fiber fineness of the ground yarn is within this range, cushioning properties similar to those of a soft polyurethane foam sheet can be obtained. When the single fiber fineness of the ground yarn is below the upper limit value, flexibility during bending is likely to be obtained. Also, a lightweight three-dimensional warp knitted fabric is likely to be obtained.

[0016] The knitting structure that forms the surface fabric is not particularly limited as long as it can form the surface fabric with a single reed, and examples include Denbi knitting, cord knitting, and Atlas knitting. Among these, Denbi knitting is preferred from the viewpoint of weight reduction, and cord knitting is preferred from the viewpoint of elongation characteristics and strength.

[0017] The knitting structure that forms the lining is not particularly limited as long as it can form the lining with a single reed, and can be the same as the knitting structure of the outer fabric. Among these, the denbi knitting structure is preferred from the viewpoint of weight reduction, and the cord knitting structure is preferred from the viewpoint of elongation characteristics and strength. The knitting structure of the lining may be the same as or different from the knitting structure of the outer fabric.

[0018] The connecting structure that links the surface fabric and the backing fabric is either a diagonal connecting structure or a truss connecting structure. In this embodiment, a diagonal connecting structure refers to a structure composed only of diagonal states, but does not include cross-shaped (X-shaped) structures. In this embodiment, a truss connecting structure refers to one that includes both orthogonal and diagonal states. By using a diagonal connecting structure or a truss connecting structure, a three-dimensional warp-knitted fabric with cushioning properties and flexibility when folded similar to that of a soft polyurethane foam sheet can be obtained. This is presumed to be because, when a three-dimensional warp-knitted fabric is folded or compressed, if the connecting structure is only an orthogonal connecting structure (a structure composed only of orthogonal states), a bending moment is generated and the connecting yarns are easily bent. In contrast, in the case of diagonal connecting structures and truss connecting structures, no bending moment is generated in the diagonal connecting yarns, and only axial forces of tension or compression act on them, thus reducing the range of motion of the connecting yarns and making it difficult for only the connecting yarns to bend.

[0019] For example, consider the case where a force indicated by arrow A compresses the three-dimensional warp-knitted fabric from the outer fabric structure 1 towards the inner fabric structure 2, as shown in Figure 1. If the connecting structure is orthogonal, the connecting yarn 3 bends easily as shown by arrow Ba in Figure 1(a), whereas in the case of diagonal connecting structure, a compressive force indicated by arrow Bb acts in the direction of extension of the connecting yarn 3, as shown in Figure 1(b), making the connecting yarn 3 difficult to bend. Therefore, the three-dimensional warp-knitted fabric has cushioning properties and flexibility when bent. It should be noted that the above explanation regarding the mechanism of action of connecting structures is a theoretical consideration and does not limit the present invention.

[0020] The oblique state means that, when viewed from the knitting direction (for example, the end of knitting direction), in other words, when viewed on a cross section perpendicular to the knitting direction, the connecting yarn is oblique to the surface of the three-dimensional warp-knitted fabric. The oblique state is achieved when, after the connecting yarn is knitted into one stitch of the front-lining fabric, it is knitted into the other stitch of the front-lining fabric, and the knitting into the stitch that is at least one well away from the stitch opposite to the first stitch. The orthogonal state means that, when viewed from the knitting direction, the connecting yarn is perpendicular to the surface of the three-dimensional warp-knitted fabric. The orthogonal state is achieved when, after the connecting yarn is knitted into one stitch of the front-lining fabric, it is knitted into the other stitch of the front-lining fabric, and the knitting into the stitch that is opposite to the first stitch. The orthogonal state includes a range of ±10° from orthogonality.

[0021] When using a truss linkage structure, the proportion (number ratio) of orthogonal linkage yarns in the overall linkage structure is preferably 50% or less. This suppresses bending of the linkage yarns, making it easier to obtain a three-dimensional warp knitted fabric with excellent non-directional cushioning and resilience, as well as flexibility when bent. The proportion of orthogonal linkage yarns in the overall linkage structure can be calculated using the following formula. Percentage of orthogonal connecting threads in the entire connective tissue (%) ={(Number of orthogonal connecting threads) / (Total number of connecting threads in the entire connective tissue)}×100

[0022] In a connected fabric, it is preferable that 50% or more of the connecting yarns diagonally intersect towards stitches 1 to 4 wells away from the opposing stitches of the front and back fabrics, and more preferably towards stitches 1 to 2 wells away. Arranging the connecting yarns in this manner makes it easier to obtain cushioning properties similar to those of a soft polyurethane foam sheet. It is also easier to obtain a lightweight three-dimensional warp knitted fabric. If the connecting yarns diagonally intersect towards stitches 5 wells or more away from the opposing stitches of the front and back fabrics, the angle between the front and back fabrics and the connecting yarns becomes acute, and the number of connecting yarns arranged between the front and back fabrics increases, which may impair cushioning and lightness.

[0023] The fiber material of the yarn used in the connecting yarn that forms the linked structure is not particularly limited, and conventionally known fibers such as natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers can be used, and two or more of these may be combined. Among these, synthetic fibers are preferred from the viewpoint of durability, and from the viewpoint of recyclability, polyester fibers or fibers made of the same material as the material that constitutes the surface material are preferred.

[0024] The yarn form used for the connecting yarns that form the linked tissue is multifilament yarn from the viewpoint of flexibility when folded, and multifilament crimped yarn from the viewpoint of flexibility when folded, cushioning and tactile feel. Multifilament crimped yarn has gaps in the yarn itself, and the crimped yarn acts like a spring or coil. Therefore, by using multifilament crimped yarn, it is possible to obtain cushioning and flexibility when folded similar to that of soft polyurethane foam.

[0025] Examples of multifilament crimped yarns include false-twisted yarns, air-processed yarns, composite yarns made by air-blending or composite false-twisting two or more constituent yarns, and latent crimped yarns such as latent crimpable conjugate yarns, which are made by joining two components with different heat shrinkage characteristics in a side-by-side or eccentric core-sheath type and can exhibit crimping by heat treatment. Among these, false-twisted yarns are preferred from the viewpoint of flexibility, cushioning and tactile feel when folded. The method of false-twisting is not particularly limited, but from the viewpoint of flexibility and cushioning when folded, a single heater (false-twisting in only one direction) is preferred.

[0026] The yarn used for the connecting yarn is preferably all multifilament crimped yarn, but multifilament non-crimped yarn and monofilament yarn may be mixed as long as the effects of the present invention are not impaired. Using monofilament yarn for the connecting yarn provides strong resilience, but if only monofilament yarn is used as the connecting yarn, the cushioning will be firmer than that of soft polyurethane foam. If the proportion of monofilament yarn or multifilament non-crimped yarn increases, the desired flexibility when folded may not be obtained. Therefore, the proportion of multifilament crimped yarn is preferably 65% ​​by mass or more, more preferably 75% by mass or more, and particularly preferably 100% by mass. The proportion of multifilament crimped yarn in the total connecting yarn can be calculated from the following formula. Percentage of multifilament crimped yarn in the total connective tissue (by mass) = {(mass of multifilament crimped yarn) / (total mass of linked yarn)} × 100

[0027] The cross-sectional shape of the connecting threads used to form the linked structure is not particularly limited and may be a normal round shape or an irregular shape. From the viewpoint of cushioning, a round cross-sectional shape of the connecting threads is preferable.

[0028] Regardless of whether the connecting yarn used to form the linked structure is a multifilament crimped yarn, a multifilament non-crimped yarn, or a monofilament yarn, the fineness (total fineness) of the yarn used for the connecting yarn is 80 to 170 dtex. Having the total fineness of the connecting yarn within this range results in softer bending rigidity compared to using monofilament yarn, thus enabling the creation of a three-dimensional warp-knitted fabric with cushioning and flexibility when folded similar to that of a soft polyurethane foam sheet. Having the total fineness of the connecting yarn above the lower limit provides cushioning similar to that of a soft polyurethane foam sheet. Having the total fineness of the connecting yarn below the upper limit makes it easier to obtain flexibility when folded. The total fineness of the connecting yarn is preferably 80 to 110 dtex.

[0029] When the connecting yarn used to form the linked structure is a multifilament crimped yarn or a multifilament non-crimped yarn, the fineness (single fiber fineness) of the fibers used in the connecting yarn is 2 to 5 dtex. Because the single fiber fineness of the connecting yarn is within this range, the bending rigidity is softer compared to when monofilament yarn is used for the connecting yarn, resulting in a three-dimensional warp-knitted fabric with cushioning and flexibility when folded similar to that of a soft polyurethane foam sheet. If the single fiber fineness of the connecting yarn is above the lower limit, cushioning similar to that of a soft polyurethane foam sheet is obtained. If the single fiber fineness of the connecting yarn is below the upper limit, flexibility when folded is easily obtained.

[0030] The number of connecting threads per unit area is not particularly limited, ranging from 1380 to 2520 threads / (24.5 mm). 2 This is preferable. By having the number of connecting threads per unit area within this range, it is easy to obtain cushioning properties and flexibility when folded similar to those of a soft polyurethane foam sheet. Furthermore, it results in a lightweight warp-knitted fabric. The number of connecting threads per unit area can be calculated using the following formula. Number of connecting threads per unit area (threads / (24.5mm)) 2 ) = (course density) × (well density) × 2

[0031] The weight of the warp-knitted fabric is 550g / m. 2 The following applies: The weight is 550g / m². 2 The following conditions result in a material that exhibits the same flexibility when folded as a soft polyurethane foam sheet. Furthermore, the three-dimensional warp-knitted fabric is lightweight. The weight of the three-dimensional warp-knitted fabric is preferably 500 g / m². 2 The following applies. The lower limit of the weight of the three-dimensional warp-knitted fabric is not particularly limited, but from the viewpoint of cushioning, it is preferably 180 g / m². 2 That's all.

[0032] The thickness of the three-dimensional warp-knitted fabric is not particularly limited, but is preferably 1 to 10 mm, and more preferably 1.8 to 5 mm. A thickness of three-dimensional warp-knitted fabric above the lower limit makes it easier to obtain the desired cushioning properties. A thickness of three-dimensional warp-knitted fabric below the upper limit allows for the creation of a lightweight three-dimensional warp-knitted fabric.

[0033] The density of the warp-knitted fabric is not particularly limited, but is preferably 30-45 courses / 25.4mm and 23-28 wells / 25.4mm. Having the density of the warp-knitted fabric within this range makes it easier to obtain cushioning properties similar to those of a soft polyurethane foam sheet. Furthermore, having the density of the warp-knitted fabric below the upper limit makes it easier to obtain flexibility when folded, similar to that of a soft polyurethane foam sheet.

[0034] The three-dimensional warp knitted fabric according to this embodiment can be knitted on a double raschel knitting machine having two opposing rows of needle beds. A gauge of 18 to 28 gauge is preferably used for the knitting machine.

[0035] Conventional post-processing can be performed on three-dimensional warp knitted fabrics (bare fabric) knitted by a double raschel knitting machine. In the case of three-dimensional warp knitted fabrics using pre-dyed yarns or yarns with undiluted dye, the bare fabric can be obtained by processes such as scouring and heat setting. If any of the ground yarns of the surface fabric, the ground yarns of the backing fabric, or the connecting yarns of the connecting fabric are uncolored, the bare fabric of the three-dimensional warp knitted fabric can be obtained by processes such as pre-setting, scouring, dyeing, and heat setting. Heat setting, which is important for controlling the density of the three-dimensional warp knitted fabric, is preferably performed using a heat setter to adjust the density of the knitted fabric and the angle of the connecting yarns by widening or widening the width. For heat setting, it is preferable to set the processing temperature to 130 to 190°C and the processing time to 1 to 3 minutes.

[0036] The three-dimensional warp-knitted fabric according to this embodiment is a three-dimensional warp-knitted fabric used by laminating it on the back surface of a surface material. The surface material can be anything that can cover the three-dimensional warp-knitted fabric and is not particularly limited. Examples of surface materials include woven fabrics, knitted fabrics, artificial leather, synthetic leather, natural leather, and sheet materials. The lamination method is also not particularly limited. Lamination methods include lamination via adhesive and lamination by sewing. When using an adhesive for lamination, it is preferable to use a hot-melt adhesive made of polyester resin from the viewpoint of recyclability.

[0037] The applications of the composite surface material, in which a three-dimensional warp-knitted fabric according to this embodiment is laminated to the back surface of a surface material, are not particularly limited. Specific examples of applications include interior materials for various vehicles, such as automotive seats and door trims, as well as interior applications such as surface materials for sofas and chairs, and fashion applications such as bags and shoes.

[0038] Furthermore, the various numerical ranges described in the specification can be any combination of their upper and lower limits, and all such combinations are described herein as preferred numerical ranges. Also, the description of a numerical range as "X~Y" means X or greater and Y or less. [Examples]

[0039] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0040] Each evaluation item was assessed according to the following method.

[0041] [Similar cushioning properties to soft polyurethane foam sheets] The cushioning properties, similar to those of a soft polyurethane foam sheet, were evaluated based on the hysteresis loss rate and rebound modulus. If both the hysteresis loss rate and rebound modulus were judged to be △ or higher, it can be said that the cushioning properties are similar to those of a soft polyurethane foam sheet.

[0042] [Hysteresis loss rate] Except for the size of the pressure plate being a flat disc with a diameter of 100 mm, the hysteresis loss rate was measured in accordance with JIS K6400-2:2012 6.8 E method (method for determining the compression deflection coefficient and hysteresis loss rate), and evaluated according to the evaluation criteria below. A score of △ or higher was considered acceptable. (Evaluation Criteria) ○: 55% or more and 65% or less △: 50% or more but less than 55%, or more than 65% but 70% or less ×: Less than 50% or more than 70%

[0043] [Rebound modulus] Multiple 100mm square test specimens were prepared, and the rebound modulus was measured in accordance with JIS K6400:1997 (Method A). The specimens were then evaluated according to the following evaluation criteria. A score of △ or higher was considered acceptable. (Evaluation Criteria) ○: 25% or more and 35% or less △: 20% or more but less than 25%, or more than 35% but 40% or less ×: Less than 20% or more than 40%

[0044] [Bending resistance] Measured in accordance with JIS L1096:2010 8.21 Rigidity A method (45° cantilever method) and evaluated according to the following evaluation criteria. Among the judgments in the well direction and the course direction of the surface (the side where the skin material is laminated), if the evaluation of the worse side is Δ or more, it can be said that it has the same flexibility when bent as the soft polyurethane foam sheet. (Evaluation criteria) ○: 145 mm or less △: More than 145 mm and 155 mm or less ×: More than 155 mm

[0045] [Lightweight] The evaluation of lightweight was carried out by measuring the basis weight and evaluated according to the following evaluation criteria. If it is Δ or more, it can be said that it is lightweight. (Evaluation criteria) ○: 180 g / m 2 or more and 500 g / m 2 or less △: Less than 180 g / m 2 or more than 500 g / m 2 and 550 g / m 2 or less ×: More than 550 g / m 2 exceeding

[0046] [Example 1] Using a double raschel knitting machine (RD6DPLM-77E-22G, manufactured by Karl Mayer Co., Ltd.) with a bobbin distance of 3 mm and 22 gauge, a full set of 84 dtex / 36 f polyester multifilament 2H false-twist yarn was used as the ground yarn to form the lining structure using a 2-needle cord knit structure (2-3 / 1-0). A full set of 84 dtex / 36 f polyester multifilament 2H false-twist yarn was used as the connecting yarn to form a diagonal connecting structure (2-1 / 2-3 / 1-2 / 1-0) to connect the surface and lining structures. A full set of 84 dtex / 36 f polyester multifilament 2H false-twist yarn was used as the ground yarn to form the surface structure using a 2-needle cord knit structure (1-0 / 2-3), thereby producing a three-dimensional warp knit fabric. The resulting three-dimensional warp-knitted fabric was heat-treated in a heat setter at 180°C for 1 minute to achieve the desired density and width. This resulted in the three-dimensional warp-knitted fabric of Example 1 (double raschel knit fabric, weight 197g / m²). 2 A thickness of 1.8 mm, density of 32 courses / 25.4 mm, and 24 wells / 25.4 mm were obtained.

[0047] [Example 2] The only differences from Example 2 were that the gap between the bobbins of the double raschel knitting machine was changed to 4 mm to produce the raw material for the three-dimensional warp knit fabric, and that the heat treatment with a heat setter was performed at 180°C for 1 minute to set the width and achieve the desired density (higher density than in Example 1). 2 A sample with a thickness of 2.7 mm, a density of 33 courses / 25.4 mm, and 26 wells / 25.4 mm was obtained.

[0048] [Example 3] The only differences from Example 3 are that the bobbin distance of the double raschel knitting machine was changed to 10 mm to produce the raw fabric of the three-dimensional warp knitted material, and that the heat treatment with a heat setter was performed at 180°C for 1 minute to set the width and achieve the desired density (higher density than in Example 1). 2A thickness of 6.0 mm, density of 44 courses / 25.4 mm, and 28 wells / 25.4 mm were obtained.

[0049] [Example 4] Except for changing the bobbin distance of the double raschel knitting machine to 5 mm and using a full set of 167 dtex / 48 f polyester multifilament 2H false-twist yarn as a connecting yarn for reed L2, the three-dimensional warp knitted fabric of Example 4 (double raschel knit fabric, weight 499 g / m²) was produced in the same manner as Example 1. 2 A thickness of 3.2 mm, density of 31 courses / 25.4 mm, and 24 wells / 25.4 mm were obtained.

[0050] [Example 5] Except for using a full set of 167dtex / 36f polyester multifilament 2H false-twist yarn as a connecting yarn on reed L2, the process was the same as in Example 4 to produce the three-dimensional warp knit fabric of Example 5 (double raschel knit fabric, weight 486g / m²). 2 A thickness of 3.1 mm, density of 31 courses / 25.4 mm, and 24 wells / 25.4 mm were obtained.

[0051] [Comparative Example 1] Comparative Example 1 was produced in the same manner as Example 1, except that the gap between the bobbins of the double raschel knitting machine was changed to 11 mm to produce the raw fabric of the three-dimensional warp knitted fabric, and in the heat treatment with a heat setter, the fabric was heat-treated at 180°C for 1 minute to set the width so that the desired density (higher density than in Example 1) could be achieved. (Double raschel knitted fabric, weight 562 g / m²) 2 A thickness of 6.7 mm, density of 44 courses / 25.4 mm, and 26 wells / 25.4 mm were obtained.

[0052] [Comparative Example 2] Using a double raschel knitting machine (RD6DPLM-77E-22G, manufactured by Karl Mayer Co., Ltd.) with a bobbin distance of 4 mm and 22 gauge, a full set of 84 dtex / 36 f polyester multifilament 2H false twist yarn was used as the ground yarn on reed L1 to form a cord knit structure (2-3 / 1-0) with a 2-needle swing, and a full set of 84 dtex / 36 f polyester multifilament 2H false twist yarn was used as the connecting yarn on reed L2. The process was carried out in the same manner as in Example 1 to form a connecting structure that links the face and back fabrics using a 1-0 / 1-0 orthogonal connecting structure, and to form the face fabric using a 2-needle cord knit structure (1-0 / 2-3) by leading the yarn in a set and leading the 84dtex / 36f polyester multifilament 2H false-twist processed yarn as the ground yarn in a full set to the reed L3 and knitting the face fabric using a 2-needle cord knit structure (1-0 / 2-3) to produce the raw material of the three-dimensional warp knit fabric of Comparative Example 2 (double raschel knit fabric, weight 243g / m²). 2 A thickness of 2.6 mm, density of 30 courses / 25.4 mm, and 23 wells / 25.4 mm were obtained.

[0053] [Comparative Example 3] The only differences from the change in the bobbin distance of the double raschel knitting machine to 4 mm, and the use of a full set of 56dtex / 24f polyester multifilament 2H false-twist yarn as a connecting yarn in reed L2, were the same as in Example 1, to produce the three-dimensional warp knitted fabric of Comparative Example 3 (double raschel knit fabric, weight 194 g / m²). 2 A thickness of 2.7 mm, density of 32 courses / 25.4 mm, and 23 wells / 25.4 mm were obtained.

[0054] [Comparative Example 4] The procedure for Comparative Example 4 was the same as in Comparative Example 3, except that a full set of 224dtex / 72f polyester multifilament 2H false-twist yarn was used as the connecting yarn for reed L2. (The three-dimensional warp knit fabric of Comparative Example 4, double raschel knit fabric, weight 543g / m²) 2 A thickness of 2.7 mm, density of 31 courses / 25.4 mm, and 23 wells / 25.4 mm were obtained.

[0055] [Comparative Example 5] The procedure for Comparative Example 5 was the same as in Comparative Example 3, except that a full set of 84dtex / 48f polyester multifilament 2H false-twist yarn was used as the connecting yarn for reed L2. (Double raschel knit fabric, weight 253g / m²) 2 A thickness of 2.6 mm, density of 33 courses / 25.4 mm, and 24 wells / 25.4 mm were obtained.

[0056] [Comparative Example 6] The same procedure as in Example 4 was followed to produce the three-dimensional warp knitted fabric (double raschel knit, weight 161g / m²) of Comparative Example 6, except that a full set of 33dtex / 6f polyester multifilament 2H false-twist yarn was used as the connecting yarn on reed L2. 2 A thickness of 3.2 mm, density of 32 courses / 25.4 mm, and 24 wells / 25.4 mm were obtained.

[0057] The details and evaluation of the three-dimensional warp-knitted fabrics obtained for Examples 1-5 and Comparative Examples 1-6 are shown in Tables 1-2.

[0058] [Table 1]

[0059] [Table 2]

[0060] Comparative Example 1 had poor flexibility and lightness when folded because the weight of the three-dimensional warp knitted fabric exceeded the upper limit. Comparative Example 2 did not achieve the same cushioning properties as soft polyurethane foam because the connecting structure was formed only of orthogonal connecting structures. Comparative Example 3 did not achieve the same cushioning properties as soft polyurethane foam because the total fineness of the connecting yarn was below the lower limit. Comparative Example 4 had poor flexibility when folded because the total fineness of the connecting yarn exceeded the upper limit. Comparative Example 5 did not achieve the same cushioning properties as soft polyurethane foam because the single fiber fineness of the connecting yarn was below the lower limit. Comparative Example 6 had poor flexibility when folded because the single fiber fineness of the connecting yarn exceeded the upper limit. In contrast, Examples 1 to 5 were lightweight, had cushioning properties similar to soft polyurethane foam, and exhibited excellent flexibility when folded. [Explanation of Symbols]

[0061] 1…Outer fabric structure, 2…Lining structure, 3…Connecting yarn

Claims

1. It is a three-piece warp knitted fabric, The aforementioned three-dimensional warp-knitted fabric consists of a face fabric structure, a backing fabric structure, and a connecting structure that connects the face fabric structure and the backing fabric structure. The connecting yarns constituting the aforementioned connecting structure are multifilament crimped yarns with a total fineness of 80 to 170 dtex and a single fiber fineness of 2 to 5 dtex. The aforementioned connecting structure is an oblique connecting structure or a truss connecting structure, Weight: 550 g / m ２ The following is a three-dimensional warp-knitted fabric.

2. A composite surface material comprising a surface material laminated onto a three-dimensional warp-knitted fabric according to claim 1.

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