Vehicle seat covering material using double knit circular knit fabric, child seat covering material using double knit circular knit fabric, and nursing bed covering material using double knit circular knit fabric

Abstract

To provide a new double knit circular knitted fabric capable of suppressing entering of dust between a front knitted fabric and a rear knitted fabric from holes on a surface at low cost.SOLUTION: A double knit circular knitted fabric 1 comprises: a front knitted fabric 10 having a stitch structure 12 of a front yarn 11; a rear knitted fabric 20 having a stitch structure 22 of a rear yarn 21; and a connection structure 30 to connect the front knitted fabric 10 and the rear knitted fabric 20 by a connecting yarn 31. The front knitted fabric 10 has a bottomed hole 40 that is recessed from a front surface 13 and linked to the rear knitted fabric 20. The front yarn 11 pulled by the rear knitted fabric 20 is disposed on a lateral surface 43 of the bottomed hole 40.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a double knit circular knit fabric. a cover material for a vehicle seat using the double knit circular knit fabric; a cover material for a child seat using the double knit circular knit fabric; and a cover material for a nursing bed using the double knit circular knit fabric. Regarding. [Background technology]

[0002] Thick double raschel knitted fabrics with a mesh structure are used as covering materials for automobile seats. These double raschel knitted fabrics have a three-dimensional structure in which a front knitted fabric with a mesh structure and a back knitted fabric are joined together with a connecting yarn. The double raschel knitted fabrics are knitted on a double raschel machine, which is a type of warp knitting machine. The multiple holes that make up the mesh structure knitted on the double raschel machine penetrate the front knitted fabric. Therefore, the back knitted fabric can be seen through each through-hole in the front knitted fabric. In the double raschel knitted fabric shown in Patent Document 1, the back knitted fabric visible from the first mesh row of the front knitted fabric and the back knitted fabric visible from the second mesh row of the front knitted fabric have different hues. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Registered Utility Model No. 3080618 Summary of the Invention [Problem to be solved by the invention]

[0004] However, double raschel knitted fabrics are expensive. Also, if debris such as candy crumbs or hair gets into the holes in the front knitted fabric, the debris may find its way between the front knitted fabric and the back knitted fabric, making it impossible to remove the debris from the double raschel knitted fabric. The above-mentioned problems may also occur in the covering materials of child seats, nursing beds, and the like.

[0005] The present invention provides a novel knitted fabric that can inexpensively prevent dust from entering between the front knitted fabric and the back knitted fabric through holes on the surface. Vehicle seat covering material, child car seat covering material, and nursing bed covering material using the sameThis discloses the following. [Means for solving the problem]

[0006] Double knit circular knit fabric of the present invention Vehicle seat covering material using teeth, a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; a double knit circular knit fabric that is a corrugated knit having a bonding structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn that is different from both the front yarn and the back yarn. Vehicle seat covering material using In The front knitted fabric has a bottomed hole that is recessed from the surface and connected to the back knitted fabric, and the front yarn that is pulled into the back knitted fabric and is different from the binding yarn is arranged on the side of the bottomed hole.

[0007] In addition, the present invention The cover material for the child car seat is made of double knit circular fabric. a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; a double knit circular knit fabric that is a corrugated knit having a bonded structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn that is different from the front yarn and the back yarn, The front knitted fabric has a bottomed hole that is recessed from the surface and connected to the back knitted fabric, and the front yarn that is pulled into the back knitted fabric and is different from the binding yarn is arranged on the side of the bottomed hole. Furthermore, the covering material of the nursing bed using the double knit circular knit fabric of the present invention is a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; A covering material for a nursing bed using a double knit circular knit fabric which is a corrugated knit having a bonding structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn which is different from the front yarn and the back yarn, The front knitted fabric has a bottomed hole recessed from the surface and connected to the back knitted fabric, and the front yarn drawn into the back knitted fabric and different from the binding yarn is arranged on the side of the bottomed hole. It has the following features. [Effects of the Invention]

[0010] According to the present invention, a novel double knit circular knit fabric can be provided that can inexpensively prevent dust from entering between the front and back knit fabrics through holes on the surface. Vehicle seat covering material, child car seat covering material, and nursing bed covering material using the same can be provided. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view schematically showing an example of a double knit circular knit fabric. [Figure 2] FIG. 1 is a diagram schematically showing an example of a structure of a double knit circular knit fabric. [Figure 3] 1 is a structure diagram schematically showing an example of knitting a double knit circular knit fabric. [Figure 4] FIG. 1 is a diagram schematically illustrating an example of a main part of a double knit circular knitting machine to which a fabric presser foot is attached. [Figure 5] FIG. 2 is a perspective view schematically showing an example of a fabric presser foot; [Figure 6] FIG. 10 is a plan view schematically showing an example of the positional relationship between the needles and the fabric presser foot. [Figure 7] Photo of double knit circular knit fabric sample. [Figure 8] 10A and 10B are diagrams illustrating a schematic example of how the intrusion of dust into the gap between the front knitted fabric and the back knitted fabric through holes on the surface is suppressed. [Figure 9] FIG. 10 is a diagram schematically showing the structure of a double raschel knitted fabric of a comparative example. [Figure 10] FIG. 10 is a diagram schematically showing a fabric presser having a hard metal plate with a chipped portion in a comparative example. [Figure 11] Photograph of a comparative double knit circular knit fabric sample. DETAILED DESCRIPTION OF THE INVENTION

[0012] The following describes embodiments of the present invention. Of course, the following embodiments are merely examples of the present invention, and not all of the features shown in the embodiments are necessarily essential to the solution of the invention.

[0013] (1) Overview of the technology included in this invention: First, an overview of the technology included in the present invention will be described with reference to the examples shown in Figures 1 to 11. Note that the figures in this application are diagrams showing schematic examples, and the magnifications in the directions shown in these figures may differ, and the figures may not be consistent. Of course, each element of the present technology is not limited to the specific example indicated by the symbol. In addition, in the present application, a numerical range "Min to Max" means a value equal to or greater than the minimum value Min and equal to or less than the maximum value Max.

[0014] [Aspect 1] 1, 2, etc., a double knit circular knit fabric 1 according to one aspect of the present technology includes a front knitted fabric 10 having a stitch structure 12 of a front yarn 11, a back knitted fabric 20 having a stitch structure 22 of a back yarn 21, and a binding structure 30 in which the front knitted fabric 10 and the back knitted fabric 20 are bound together with a binding yarn 31. The front knitted fabric 10 has a bottomed hole 40 recessed from a surface 13 and connected to the back knitted fabric 20, with the front yarn 11 drawn into the back knitted fabric 20 being arranged on a side surface 43.

[0015] Because the front knitted fabric 10 and the back knitted fabric 20 are bonded together with the bonding yarn 31, the double knit circular fabric 1 is thick and can be used as a corrugated knit (carton knit) or the like. The front knitted fabric 10, which has a stitch structure 12 of the front yarn 11, which is the weft yarn, has a bottomed hole 40 that is recessed from the surface 13 and connected to the back knitted fabric 20, and the front yarn 11 drawn into the back knitted fabric 20 is arranged on the side 43 of the bottomed hole 40. As a result, even if debris such as candy crumbs 301 or hair 302 enters the bottomed hole 40, the intrusion of the debris between the front knitted fabric 10 and the back knitted fabric 20 is suppressed, as shown in Figure 8.

[0016] 9 schematically shows the structure of a double raschel knitted fabric 801 of a comparative example. The double raschel knitted fabric 801 comprises a front knitted fabric knitted so as to have a plurality of through-holes by swinging the front yarn 11, which is the warp, in the weft direction; a back knitted fabric knitted by swinging the back yarn 21, which is the warp, in the weft direction; and a binding structure in which the front knitted fabric and the back knitted fabric are bound together with a binding yarn 31. Due to the structure of the double raschel machine, the front yarn 11 does not turn to the back, so the binding yarn 31 appears on the side of a hole 840 visible in the front knitted fabric. For this reason, if debris such as candy crumbs 301 or hair 302 enters the hole 840, the debris (301, 302) will get between the front knitted fabric and the back knitted fabric, and it may be impossible to remove this debris (301, 302) from the double raschel knitted fabric 801.

[0017] In the double knit circular fabric 1 exemplified in Figure 8 etc., the front yarn 11 pulled into the back fabric 20 is arranged on the side surface 43 of the bottomed hole 40, which prevents dust from entering between the front fabric 10 and the back fabric 20 through the bottomed hole 40. Therefore, the above-mentioned mode 1 can provide a novel double knit circular fabric that can inexpensively prevent dust from entering between the front fabric and the back fabric through holes on the surface.

[0018] Here, a blind hole means a hole having a bottom. The front yarn is pulled into the back knitted fabric at the bottom of the blind hole of the front knitted fabric, and the blind hole has a size equal to or larger than one course in the warp (vertical) direction. The above remarks also apply to the following aspects.

[0019] [Aspect 2] There may be a plurality of blind holes 40. The surface 13 of the front knitted fabric 10 may have a pattern 14 formed by the plurality of blind holes 40. This embodiment can provide a novel double knit circular knitted fabric having a pattern on its surface formed by the plurality of blind holes.

[0020] [Aspect 3] The plurality of bottomed holes 40 may include bottomed grooves 44 whose longitudinal direction is oriented in the warp direction D2. This embodiment can provide a novel double knit circular knit fabric having bottomed grooves on its surface whose longitudinal direction is oriented in the warp direction.

[0021] [Aspect 4] A knitted product according to one aspect of the present technology is a knitted product using the double knit circular fabric 1. This aspect can provide a knitted product using a novel double knit circular fabric that can inexpensively prevent dust from entering between the front knitted fabric and the back knitted fabric through holes on the surface. Here, knitted products include products in which double knit circular fabric is cut into a product shape, products in which the edges of cut double knit circular fabric are processed by sewing or the like, and products in which cut double knit circular fabrics are sewn together. Knitted products may include accessories other than the double knit circular fabric. Knitted products include covering materials for vehicle seats, covering materials for child seats, covering materials for nursing beds, etc.

[0022] The double knit circular knitting fabric 1 described above can be produced by a double knit circular knitting machine 200, as illustrated in FIG. 4, which includes a cylinder 210 on which a plurality of cylinder needles 211 are arranged, a dial 220 on which a plurality of dial needles 221 are arranged, a needle selector 230, and a support 240 located outside the cylinder 210. If the double knit circular knitting fabric 1 is thick, such as a corrugated knit, it is necessary to raise the position of the dial 220 to widen the gap between the cylinder 210 and the dial 220. If the position of the dial 220 is raised, the knitted fabric 50 connected to the knitting yarn 51 will be lifted, and without a fabric presser, the knitting yarn 51 may become tangled. Therefore, it is conceivable to attach a fabric presser to the support 240 to hold the knitted fabric 50 at a presser position P1 between the plurality of cylinder needles 211 and the plurality of dial needles 221 to prevent the knitting yarn 51 from becoming tangled.

[0023] In order to knit a double knit circular fabric having a pattern such as a bottomed hole 40, a fabric presser having a hard metal plate connected from the presser base attached to the support 240 to the presser position P1 was attached to the support 240, and it was found that defects occurred in the double knit circular fabric. Figure 10 shows a schematic diagram of a knitted fabric presser 900 of a comparative example. The knitted fabric presser 900 is equipped with a hard metal plate 920 that holds the knitted fabric so that the knitting yarn does not become entangled between the multiple cylinder needles and the multiple dial needles. As shown in the area enclosed by the two-dot chain line in Figure 10, the cross section of the hard metal plate 920 is approximately rectangular. When the knitted fabric presser 900 was inspected, it was confirmed that a portion 930 had been scraped off on the vertical surface of the hard metal plate 920 on the cylinder needle side due to the cylinder needle hitting it.

[0024] FIG. 11 shows a photograph of a comparative double knit circular knit fabric sample. When the operation of the double knit circular knitting machine was checked, it was confirmed that defects such as yarn breakage shown in Figure 11 occurred in the double knit circular knitting fabric when the knitting yarn got caught on the scraped portion 930 of the hard metal plate 920.

[0025] Therefore, it is desirable to prevent defects from occurring in the double knit circular fabric due to the knitting yarn getting caught in the scraped portion of the knitting presser.

[0026] [Aspect 5] A method for manufacturing a double knit circular fabric according to one embodiment of the present technology is a method for manufacturing a double knit circular fabric 1 using a double knit circular knitting machine 200, as illustrated in Figures 3 and 4, which is equipped with a cylinder 210 on which a plurality of cylinder needles 211 are arranged, a dial 220 on which a plurality of dial needles 221 are arranged, a needle selection device 230, and a support 240 located outside the cylinder 210, and includes the following steps. (a1) Holding process ST1 in which a spring steel wire 120 connected from a presser base 110 attached to the support 240 to a presser position P1 between the plurality of cylinder needles 211 and the plurality of dial needles 221 holds the knitted fabric 50 so that the knitting yarn 51 does not become entangled at the presser position P1. (a2) A control process ST2 that controls the operation of the plurality of cylinder needles 211 and the plurality of dial needles 221 and the supply of the knitting yarn 51 so as to knit the double knit circular fabric 1, which comprises a front knitted fabric 10 having a stitch structure 12 of a front yarn 11 contained in the knitting yarn 51, a back knitted fabric 20 having a stitch structure 22 of a back yarn 21 contained in the knitting yarn 51, and a bonding structure 30 in which the front knitted fabric 10 and the back knitted fabric 20 are bonded together with a bonding yarn 31 contained in the knitting yarn 51, the front knitted fabric 10 having a bottomed hole 40 recessed from the surface 13 and connected to the back knitted fabric 20, and the front yarn 11 drawn into the back knitted fabric 20 being arranged on the side 43 of the bottomed hole 40.

[0027] Even if the needle hits the spring steel wire 120, the spring steel wire 120 bends due to its elasticity, preventing specific locations on the spring steel wire 120 from being scraped off. This makes it possible to produce a double knit circular fabric 1 in which defects caused by the knitting yarn 51 getting caught in scraped locations on the fabric presser are prevented. In the obtained double knit circular fabric 1, the face yarn 11 is arranged on the side surface 43 of the bottomed hole 40 that is recessed from the surface 13 and connected to the back knit fabric 20, preventing dust from entering between the face knit fabric 10 and the back knit fabric 20 through the bottomed hole 40. Therefore, the above embodiment can provide a method for producing a double knit circular fabric that can inexpensively prevent dust from entering between the face knit fabric 10 and the back knit fabric 20 through holes on the surface. Here, the spring steel wire includes piano wire, stainless steel wire for springs, hard steel wire usable for springs (for example, oil-tempered wire for springs), etc. This remark also applies to the following aspects.

[0028] [Aspect 6] The spring steel wire 120 may have an oval cross section with a maximum diameter of 0.7 to 1.2 mm, including a circular cross section with a diameter of 0.7 to 1.2 mm. In the above cases, the spring steel wire 120 having an elliptical cross section (including a circular cross section) that is struck by the cylinder needle 211 escapes to the side of the cylinder needle 211, further preventing abrasion of a specific portion of the spring steel wire 120. Therefore, the above embodiment can further prevent defects in the double knit circular fabric caused by the knitting yarn getting caught in a portion that has been abraded by the fabric presser.

[0029] [Aspect 7] The fabric presser 100, which includes the presser base 110 and the spring steel wire 120, suppresses the above-mentioned defects in the double knit circular fabric 1 and realizes a double knit circular fabric 1 that can inexpensively prevent dust from entering between the front knitted fabric 10 and the back knitted fabric 20 through holes in the surface 13. The fabric presser 100 according to one aspect of the present technology is attached to the double knit circular knitting machine 200, and holds the knitted fabric 50 at a presser position P1 between the plurality of cylinder needles 211 and the plurality of dial needles 221 to prevent entanglement of the knitting yarn 51. The fabric presser 100 includes the presser base 110 attached to the support body 240, and a spring steel wire 120 connected from the presser base 110 to the presser position P1 so as to hold the knitted fabric 50 at the presser position P1.

[0030] Even if the needle hits the spring steel wire 120, the spring steel wire 120 bends due to its elasticity, thereby preventing specific locations from being scraped off the spring steel wire 120. Therefore, the above-described embodiment can provide a fabric presser that can prevent defects in a double knit circular fabric caused by the knitting yarn getting caught in a scraped location in the fabric presser. As described above, the spring steel wire 120 may have an oval cross section with a maximum diameter of 0.7 to 1.2 mm, including a circular cross section with a diameter of 0.7 to 1.2 mm.

[0031] (2) Examples of double knit circular knit fabrics: Fig. 1 shows a typical example of a double knit circular fabric 1 used as an upholstery material for vehicle seats, etc. Fig. 2 shows a typical example of the structure of the double knit circular fabric 1. Note that the drawings shown in this application are merely schematic diagrams for explaining the specific examples in an easy-to-understand manner. For example, the thickness of the double knit circular fabric 1 is exaggerated in Fig. 1, and the stitch structures 12 and 22 shown in Fig. 2 are simplified. The double knit circular knit fabric 1 shown in Figures 1 and 2 is a thick corrugated knit comprising a front knit fabric 10, a back knit fabric 20, and a co-knit structure 30. The double knit circular knit fabric 1 of this example is a novel corrugated knit having blind holes 40 recessed from the surface 13 of the front knit fabric 10, and is knitted by a double knit circular knitting machine 200 equipped with a novel fabric presser 100 as shown in Figures 4 to 6. Figure 1 shows that the surface 13 has a mesh pattern as a pattern 14 formed by the plurality of blind holes 40.

[0032] The double knit circular knit fabric 1 has a design along the weft direction D1 as shown in Fig. 2. When the design shown in Fig. 2 is repeated in the warp direction D2 that intersects with the weft direction D1, bottomed grooves 44 with their longitudinal directions facing the warp direction D2 are formed as bottomed holes 40.

[0033] The front knitted fabric 10 has a stitch structure 12 of the front yarn 11, which is a weft yarn. The back knitted fabric 20 has a stitch structure 22 of the back yarn 21, which is a weft yarn. The binding structure 30 is a tuck structure in which the front knitted fabric 10 and the back knitted fabric 20 are bound together by the binding yarn 31, which is a weft yarn. The front knitted fabric 10 has a bottomed hole 40 that is recessed from the front surface 13 and connected to the back knitted fabric 20. At the position of the bottomed hole 40, the front yarn 11 is caught by the stitch structure 22 of the back yarn 21 and drawn in. As a result, the bottomed hole 40 has an opening 41 on the front surface 13, the portion of the front yarn 11 that is caught on the back knitted fabric 20 is at the bottom 42 of the bottomed hole 40, and the front yarn 11 drawn into the back knitted fabric 20 is arranged on the side surface 43 of the bottomed hole 40. Since the front yarn 11 is pulled into the back knitted fabric 20, even if dust (301, 302) enters the bottomed hole 40 as shown in Figure 8, the intrusion of the dust between the front knitted fabric 10 and the back knitted fabric 20 is suppressed.

[0034] The types of the front yarn 11, back yarn 21, and binding yarn 31 are not particularly limited. For the front yarn 11, back yarn 21, and binding yarn 31, synthetic fiber filaments, synthetic fiber spun yarns, natural fiber spun yarns, blended yarns, twisted yarns, mixed yarns, etc. can be used. As synthetic fibers, polyester fibers, polyamide fibers, acrylic fibers, polyolefin fibers, etc. can be used. As natural fibers, wool, cotton, linen, etc. can be used. Yarn dyed in advance may be used for these yarns. The thicknesses of the front yarn 11, back yarn 21, and binding yarn 31 are also not particularly limited. Of course, different types of yarns may be used for the front yarn 11, back yarn 21, and binding yarn 31. The stitch structures 12, 22 can be various structures such as plain knit structure, rib knit structure, purl knit structure, and the like.

[0035] The depth of the bottomed holes 40 can be, for example, 1.0 to 4.0 mm. To make the bottomed holes 40 deeper, the dial 220 (see FIG. 4) can be raised to make the double knit circular fabric 1 thicker. To make the bottomed holes 40 shallower, the dial 220 can be lowered to make the double knit circular fabric 1 thinner.

[0036] (3) Examples of double knit circular knitting methods: Figure 3 is a schematic diagram illustrating a knitting structure of a double knit circular fabric 1. The upper part of Figure 3 shows the needle arrangement for feeders F1 to F4 in the portion of the course where a blind hole 40 is formed. The lower part of Figure 3 shows the needle arrangement for feeders F1 to F4 in the portion of the course where a blind hole 40 is not formed. In each needle arrangement, the arrangement of cylinder needles 211 is shown on the lower side, and the arrangement of dial needles 221 is shown on the upper side. The control step ST2 is performed according to the structure diagram shown in Figure 3.

[0037] Feeder F1 supplies a knotting yarn 31 for the tuck structure to some of the needles (211, 221). Feeder F2, which follows feeder F1, supplies the knotting yarn 31 for the tuck structure to needles (211, 221) that are located at a position different from the yarn feeding position from feeder F1. Feeder F3, which follows feeder F2, supplies a front yarn 11 to dial needles 221. The dial needles 221 knit a stitch structure 12 of the front yarn 11. The structure corresponding to feeder F3 includes a tuck structure. Feeder F4, which follows feeder F3, supplies a back yarn 21 to cylinder needles 211. The cylinder needles 211 knit a stitch structure 22 of the back yarn 21. The front yarn 11 supplied from feeder F3 is drawn into the stitch structure 22 of the back yarn 21 at the position of the bottomed hole 40. As a result of the above, a tubular double knit circular fabric 1 is knitted in which the front knitted fabric 10 and the back knitted fabric 20 are bound together by the binding yarn 31. In this double knit circular fabric 1, the front knitted fabric 10 having the bottomed holes 40 is on the inside.

[0038] When forming one course of blind holes 40 in the warp direction D2, knitting "without blind holes" shown in the lower part of Fig. 3, knitting one course of "with blind holes" shown in the upper part of Fig. 3, and knitting "without blind holes" shown in the lower part of Fig. 3 are performed in this order. When forming a blind groove 44, the knitting shown in the upper part of Fig. 3 is repeated for multiple courses. When forming N courses of blind holes 40 in the warp direction D2, knitting "without blind holes", knitting N courses of "with blind holes", and knitting "without blind holes" are performed in this order. N is an integer of 2 or more.

[0039] FIG. 4 shows a schematic diagram of a main part of a double knit circular knitting machine 200 for knitting the double knit circular fabric 1. As shown in FIG. The double knit circular knitting machine 200 includes a cylinder 210 on which a plurality of cylinder needles 211 are arranged, a dial 220 on which a plurality of dial needles 221 are arranged, a needle selector 230, and a support 240 located outside the cylinder 210. Each cylinder needle 211 is a latch needle in which a hook 212 at the tip is opened and closed by a latch 213, and is arranged so as to be able to move vertically back and forth relative to the cylinder 210. Each dial needle 221 is a latch needle in which a hook 222 at the tip is opened and closed by a latch 223, and is arranged so as to be able to move horizontally back and forth relative to the dial 220. In the example shown in FIG. 3 , the knitting yarn 51 caught on the cylinder needle 211 is the front yarn 11 or the knotting yarn 31, and the knitting yarn 51 caught on the dial needle 221 is the back yarn 21 or the knotting yarn 31. The dial 220 is supported on a support portion (not shown) of the double knit circular knitting machine 200 so as to be able to change its height. The needle selector 230 individually controls the operation of the cylinder needles 211. The needle selector 230 may also individually control the operation of the dial needles 221. The double knit circular knitting machine 200 is equipped with a control unit including, for example, a CPU (Central Processing Unit), a ROM (Read Only Memory), and a RAM (Random Access Memory). The needle selector 230 individually controls the operation of the needles in accordance with signals from the control unit.

[0040] If the double knit circular fabric 1 is thick, it is necessary to raise the position of the dial 220 to widen the gap between the cylinder 210 and the dial 220. If the position of the dial 220 is raised, the knitted fabric 50 connected to the knitting yarn 51 may be lifted, which may cause the knitting yarn 51 to become tangled. Therefore, a knitting fabric presser 100 is attached to the upper surface 241 of the support body 240 at a presser position P1 between the multiple cylinder needles 211 and the multiple dial needles 221 to hold the knitted fabric 50 so that the knitting yarn 51 does not become tangled.

[0041] However, when a fabric presser 900 of a comparative example shown in Fig. 10 was attached to the support 240 to knit a double knit circular fabric having a pattern such as a bottomed hole 40, it was found that defects such as those shown in Fig. 11 occurred in the double knit circular fabric sample. The fabric presser 900 shown in Fig. 10 has a hard metal plate 920 that connects the presser base attached to the upper surface 241 shown in Fig. 4 to the presser position P1. On the vertical surface of the hard metal plate 920 on the cylinder needle side, a scraped area 930 caused by the cylinder needle hitting the hard metal plate 920 was confirmed. When the operation of the double knit circular knitting machine 200 was confirmed, it was confirmed that the knitting yarn 51 was caught in the scraped area 930 on the hard metal plate 920, causing the defect shown in Fig. 11 to occur in the double knit circular fabric.

[0042] The knitting yarn 51 is supplied from the feeder to the needles (211, 221) at a constant speed by a yarn feeding device. When the double knit circular knit fabric is a plain corrugated knit that does not have a pattern such as bottomed holes 40, the cylinder needles 211 operate regularly in addition to the dial needles 221, so the knitting yarn 51 does not pull the cylinder needles 211 toward the inside of the cylinder 210. As a result, the cylinder needles 211 protruding from the cylinder 210 do not hit the hard metal plate 920.

[0043] When the double knit circular fabric has a pattern such as a blind hole 40, the amount by which the cylinder needles 211 protrude from the cylinder 210 becomes irregular, and the knitting yarn 51 may pull the cylinder needles 211 inward of the cylinder 210. For example, if the amount by which the cylinder needles 211 protrude from the cylinder 210 is small, the knitting yarn 51 becomes loose, and if the amount by which the cylinder needles 211 protrude from the cylinder 210 is large, the knitting yarn 51 pulls the cylinder needles 211 inward. When the cylinder needles 211 move inward and hit the hard metal plate 920, scraped portions 930 are created on the hard metal plate 920. For these reasons, double knit circular knitting machines equipped with the knitting presser 900 do not manufacture double knit circular fabrics having a pattern such as the bottomed holes 40. On the other hand, double raschel knitted fabrics having a mesh structure are expensive.

[0044] In this example, a fabric presser 100 equipped with a spring steel wire 120 that holds the knitted fabric 50 at a presser position P1 is attached to a double knit circular knitting machine 200. As a result, the holding step ST1 shown in Fig. 4 is performed, and the control step ST2 shown in Fig. 3 is performed, thereby obtaining a new double knit circular fabric that has a pattern but is free of defects.

[0045] Fig. 5 shows a schematic example of a fabric presser foot 100 attached to a double knit circular fabric 1. Fig. 6 shows a schematic example of the positional relationship between the needles (211, 221) and the fabric presser foot 100. The fabric presser 100 includes a presser base 110 and a spring steel wire 120. The presser base 110 includes a horizontal surface portion 111 having a vertical hole 112, a vertical shaft portion 113 having a horizontal through-hole 114, and a steel wire support portion 115. In FIG. 5 , the hole 112 is hidden by the vertical shaft portion 113. The spring steel wire 120 includes a base portion 121 supported by the steel wire support portion 115, a fabric holding portion 123 disposed at the presser position P1, and a bent portion 122 that turns from the base portion 121 and connects to the fabric holding portion 123. The steel wire support portion 115 supports the base portion 121 so that the fabric holding portion 123 holds the fabric 50 at the presser position P1, and is fixed to the vertical shaft portion 113 by a screw SC3 that passes through the through-hole 114. The vertical shaft portion 113 is fixed to the horizontal surface portion 111 by a screw SC2 with its lower portion inserted in the hole 112. The horizontal surface portion 111 is fixed to the upper surface 241 of the support body 240 by a screw SC1 so that the fabric holding portion 123 holds the fabric 50 at the pressing position P1. In this way, the presser tool base 110 is attached to the support body 240, and the spring steel wire 120 connected from the presser tool base 110 to the pressing position P1 holds the fabric 50 at the pressing position P1.

[0046] The spring steel wire 120 can be made of elastic steel wire, such as piano wire, stainless steel spring wire, or hard steel wire suitable for springs. Piano wire is typically made of high-quality piano wire material with a carbon content of 0.60 to 0.95%, and has stable elasticity suitable for use in high-grade springs. Therefore, piano wire is a preferred material for the spring steel wire 120. Because the spring steel wire 120 has the elasticity required for a spring, the spring steel wire 120 bends when it is struck by the cylinder needle 211, thereby preventing scraping of the spring steel wire 120. This results in a patterned double knit circular knit fabric 1 that is less susceptible to defects caused by the knitting yarn 51 getting caught in scraped areas by the fabric presser.

[0047] The cross section of the spring steel wire 120 is preferably elliptical, including circular. When the cross section of the hard metal plate 920 is substantially rectangular, as in the comparative example shown in Fig. 10, the cylinder needles 211 irregularly projecting from the cylinder 210 hit the corners of the hard metal plate 920, easily causing chipped portions 930 at the corners of the hard metal plate 920. The spring steel wire 120, which has an elliptical, including circular, cross section, has no corners, so even if the cylinder needles 211 hit the spring steel wire 120, the spring steel wire 120 is less likely to be chipped. When the cross section of the spring steel wire 120 is elliptical, including circular, the spring steel wire 120 escapes to the side of the cylinder needles 211, thereby preventing chipping of specific portions of the spring steel wire 120.

[0048] The diameter d1 of the spring steel wire 120 having a circular cross section is preferably 0.7 mm or more in order to hold the knitted fabric 50 at the presser position P1 and prevent the knitting yarn 51 from tangling. When the spring steel wire 120 has an elliptical cross section, the maximum diameter of the cross section of the spring steel wire 120 is preferably 0.7 mm or more. Furthermore, the diameter d1 of the spring steel wire 120 having a circular cross section is preferably 1.2 mm or less in order to allow the spring steel wire 120 that hits the cylinder needle 211 to easily escape to the side of the cylinder needle 211. When the spring steel wire 120 has an elliptical cross section, the maximum diameter of the cross section of the spring steel wire 120 is preferably 1.2 mm or less. The diameter d1 or maximum diameter of the cross section of the spring steel wire 120 may be adjusted depending on the gauge of the double knit circular knitting machine 200 and the thickness of the knitting yarn 51.

[0049] As shown in Figure 4, the pressing position P1 is preferably a position where the knitted fabric holding portion 123 (spring steel wire 120) enters at least a part of the area A1 inside the line connecting the position P2 where the cylinder needle 211 comes out of the cylinder 210 and the position P3 where the dial needle 221 comes out of the dial 220. As shown in Fig. 6, the fabric holding part 123 covers a needle entry / exit range A2 through which the needles (211, 221) advance and retreat in response to yarn supply from the feeder. The length L1 (see Fig. 5) of the fabric holding part 123 is preferably longer than the needle entry / exit range A2. When the length of the needle entry / exit range A2 is 1 inch, the length L1 of the fabric holding part 123 can be, for example, 26 to 40 mm, more preferably 27 to 35 mm, and even more preferably 28 to 30 mm.

[0050] The above-mentioned fabric presser foot 100 is attached to the support 240 so that the fabric holding part 123 is located at the presser position P1 in the needle entry / exit range A2 corresponding to the feeder where the knitting operation is performed. For example, in the organization diagram shown in Fig. 3, the fabric presser foot 100 is attached to the support 240 so that the fabric holding part 123 is located at the presser position P1 in the needle entry / exit range A2 corresponding to the feeders F3 and F4 where the knitting operation is performed.

[0051] A double knit circular fabric 1 having a pattern such as a blind hole 40 is manufactured by performing a holding step ST1 and a control step ST2 in a double knit circular knitting machine 200. In the holding step ST1, the spring steel wire 120 holds the knitted fabric 50 at the presser position P1 so that the knitting yarn 51 does not become entangled. In the control step ST2, the double knit circular knitting machine 200 (particularly the control unit and needle selector 230) controls the operation of the multiple cylinder needles 211 and multiple dial needles 221 and the supply of the knitting yarn 51 so that a double knit circular fabric 1 having a blind hole 40 is knitted. As a result, a new double knit circular fabric 1 is knitted in which the face yarn 11 is arranged on the side surface 43 of the blind hole 40 that is recessed from the front surface 13 and connected to the back fabric 20.

[0052] The spring steel wire 120 that is hit by the cylinder needle 211 pulled by the knitting yarn 51 bends due to its elasticity, thereby preventing specific locations on the spring steel wire 120 from being scraped off. This makes it possible to manufacture a novel double knit circular fabric 1 that prevents defects caused by the knitting yarn 51 getting caught in a scraped location on the fabric presser. The obtained double knit circular fabric 1 has the face yarn 11 arranged on the side surface 43 of the bottomed hole 40, as shown in Figures 1 and 2.

[0053] FIG. 7 shows a photograph of a sample obtained by actually knitting a double knit circular fabric having multiple bottomed holes 40 according to the organization diagram shown in FIG. 3. The multiple bottomed holes 40 in the double knit circular knit fabric sample shown in FIG. 7 include one course of bottomed holes 40a in the warp direction D2, two courses of bottomed grooves 44a in the warp direction D2, and six courses of bottomed grooves 44b in the warp direction D2. FIG. 7 shows that a mesh pattern is formed on the surface of the double knit circular knit fabric sample as a design created by the multiple bottomed holes. The double knit circular knit fabric sample shown in FIG. 7 does not exhibit any defects, as shown in the comparative example in FIG. 11. Therefore, it was confirmed that by attaching a fabric presser 100 equipped with a spring steel wire 120 to a double knit circular knitting machine 200, a new double knit circular knit fabric 1 having a pattern but without defects can be produced.

[0054] In the double raschel knitted fabric 801 of the comparative example shown in Figure 9, the front yarn 11 is not pulled into the back knitted fabric due to the structure of the double raschel machine. In this case, if debris (301, 302) enters the hole 840 visible in the front knitted fabric, the debris (301, 302) will get between the front knitted fabric and the back knitted fabric. As a result, it may not be possible to remove the debris (301, 302) from the double raschel knitted fabric 801.

[0055] In the double knit circular fabric 1 shown in Figure 8, the front yarn 11 is arranged on the side surface 43 of the bottomed hole 40, which prevents dust (301, 302) from entering between the front fabric 10 and the back fabric 20 through the bottomed hole 40. Therefore, the double knit circular fabric 1 is a novel knitted fabric that can inexpensively prevent dust from entering between the front fabric and the back fabric through holes on the surface. 3, it is possible to easily knit a double knit circular fabric 1 having bottomed grooves 44 with the longitudinal direction oriented in the warp direction D2. Therefore, this example can easily provide a novel double knit circular fabric having bottomed grooves on the surface with the longitudinal direction oriented in the warp direction.

[0056] (4) Examples of knitted products: Knitted products using the double knit circular fabric 1 include covering materials for automobile seats, covering materials for child seats, covering materials for nursing care beds, etc. Knitted products as seat covering materials can be manufactured, for example, by cutting the double knit circular fabric 1 to fit the shape of the seat and processing the edges of the cut double knit circular fabric by sewing or the like. Knitted products such as seat covering materials may be manufactured by sewing together multiple cut double knit circular fabrics. Knitted products may also be manufactured by sewing accessories to the cut double knit circular fabric.

[0057] (5) Variation: The present invention can be modified in various ways. For example, when the needle selector 230 controls the operation of the dial needles 221 individually, it is possible to knit a cylindrical double knit circular fabric 1 in which the front knitted fabric 10 having the blind holes 40 is on the outside. When the needle selector 230 individually controls the operations of both the cylinder needles 211 and the dial needles 221, it is possible to knit a double knit circular fabric having bottomed grooves whose longitudinal direction is oriented in the weft direction D1. Furthermore, it is also possible to form double knit circular fabrics having bottomed holes 40 for multiple courses in the warp direction D2 and multiple wales in the weft direction D1, or having bottomed holes 40 with more complex shapes. The presser tool base 110 of the knitted fabric presser tool 100 is not limited to a combination of three members (111, 113, 115). For example, a member in which the horizontal surface portion 111 and the vertical shaft portion 113 are inseparably formed as one unit may be used for the presser tool base 110, or a member in which the vertical shaft portion 113 and the steel wire support portion 115 are inseparably formed as one unit may be used for the presser tool base 110. Of course, the presser tool base 110 may be a member in which the three portions (111, 113, 115) are inseparably formed as one unit. The shape of the spring steel wire 120 can be changed as appropriate as long as the spring steel wire 120 includes the fabric holding portion 123. For example, the spring steel wire 120 may be composed of the fabric holding portion 123 and a connecting portion that changes direction from the presser tool base 110 and is connected to the fabric holding portion 123.

[0058] (6) Conclusion: As explained above, according to the present invention, in various aspects, it is possible to provide a novel double knit circular fabric that can inexpensively prevent dust from entering between the front and back knit fabrics through holes in the surface, a knitted product using the double knit circular fabric, a method for manufacturing the double knit circular fabric, a fabric presser foot used in the manufacturing method, etc. Of course, even a technology consisting only of the constituent elements of the independent claims can achieve the basic functions and effects described above. Furthermore, it is possible to implement configurations in which the components disclosed in the above examples are substituted with each other or the combination is changed, or configurations in which the components disclosed in the publicly known techniques and the above examples are substituted with each other or the combination is changed, etc. The present invention also includes these configurations. [Explanation of symbols]

[0059] 1...Double knit circular knit fabric, 10...front knitted fabric, 11...front yarn, 12...knit structure, 13...surface, 14...pattern, 20...back knitted fabric, 21...back yarn, 22...knit structure, 30...binding structure, 31...binding thread, 40...bottomed hole, 41...opening, 42...bottom, 43...side, 44...bottomed groove, 50...knitted fabric, 51...knitted yarn, 100...knitted fabric presser 110...holding tool base, 120... spring steel wire, 123... knitted fabric holding portion, 200...Double knit circular knitting machine, 210...cylinder, 211...cylinder needle, 220...Dial, 221...Dial hand, 230...needle selection device, 240...Support, 241...Top surface, A1...area, A2...needle entry / exit range, D1...latitude direction, D2...longitude direction, d1...diameter, F1~F4...feeder, L1: length, P1: Pressing position, ST1...holding process, ST2...control process.

Claims

1. a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; A covering material for a vehicle seat using a double knit circular knitted fabric which is a corrugated knit having a bonding structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn which is different from both the front yarn and the back yarn, The outer knitted fabric has a blind hole recessed from the surface and connected to the inner knitted fabric, and the outer yarn, which is drawn into the inner knitted fabric and is different from the binding yarn, is arranged on the side of the blind hole.

2. a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; a double knit circular knit fabric that is a corrugated knit having a bonded structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn that is different from the front yarn and the back yarn, The outer knitted fabric has a bottomed hole recessed from the surface and connected to the back knitted fabric, and the outer yarn, which is pulled into the back knitted fabric and is different from the binding yarn, is arranged on the side of the bottomed hole.

3. a front knitted fabric having a stitch structure of a front yarn; a back knitted fabric having a back yarn stitch structure; A covering material for a nursing bed using a double knit circular knit fabric which is a corrugated knit having a bonding structure in which the front knitted fabric and the back knitted fabric are bonded together with a bonding yarn which is different from the front yarn and the back yarn, The surface material for a nursing bed is made of a double knit circular knit fabric, and the surface knit fabric has a bottomed hole that is recessed from the surface and connected to the back knit fabric, and the surface yarn that is pulled into the back knit fabric and is different from the bonding yarn is arranged on the side of the bottomed hole.

Images