DOUBLE RASCHEL KNITTED FABRIC

- SEIREN CO., LTD.

A double raschel knitted fabric is disclosed which is excellent in a strength although openings are formed. A double raschel knitted fabric is provided including outer/lining textures and a joining portion that connects them to each other, in which the outer texture has openings, and a total overlapping fineness of sinker loops in the lining texture, which is calculated by the following calculation formula, is 400 dtex to 1800 dtex. The total overlapping fineness of sinker loops (dtex)−ΣK−1n (The fineness of a ground yarn fed from a kth guide bar (dtex))   [Eq. 1] (The number of underlaps of the ground yarn fed from the kth guide bar) (The threading ratio of the kth guide bar)

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Description
Technical Field

The present invention relates to a double raschel knitted fabric.

Background Art

As a double raschel knitted fabric has conventionally been known in which an outer texture and a lining texture are connected by a joining portion composed of joining yarns, a fabric in which a large number of openings is formed in the outer texture or the lining texture. For example, in the invention in Patent Document 1, these openings function as ventilation holes. In general, these openings are formed by knit textures, and pass through the outer texture or the lining texture of the double raschel knitted fabric.

However, due to formation of the openings, the strength of the double raschel knitted fabric is reduced. In addition, when the double raschel knitted fabric in which the openings are formed is used for a long time, there is a concern that the strength of a. ground texture in which the openings are formed may be further reduced.

Meanwhile, attempts have been made to improve the Strength in general warp knitted fabrics as well as double raschel knitted fabrics. For example, Patent Document 2 suggests “a cloth spring material composed of a warp knitted fabric in which multi-filaments account for 95 wt % or more, which is a warp knitted cloth spring material characterized in that a ground texture of the corresponding warp knitted fabric is composed by at least three or more guide bars, in which at least one guide bar forms chain stitching, at least two guide bars form tricot knitting with 1- to 8-needle swings, swing directions of at least two guide bars forming the. corresponding tricot knitting are different from each other, and the relationship between the number of courses (C) and the number of wales (W) in the ground texture is 0.8 W≤C≤1.5 W.”According to the description in Patent Document 2, the. warp knitted. cloth spring material with these characteristics has a high surface rigidity and a high strength.

PRIOR ART DOCUMENT Patent Document

[Patent Document 1] Japanese Laid-Open Patent Publication No. 2016-43062

[Patent Document 2] Japanese Laid-Open Patent Publication No. 2013-7143

DISCLOSURE OF THE INVENTION Problem that the Invention is to Solve

The present invention has been made as one of the above attempts, and an object thereof is to provide a double raschel knitted fabric excellent in a strength although openings are formed.

Means for Solving the Problem

The double raschel knitted fabric of the present invention includes outer/lining textures and a joining portion that connects them to each other, in which the outer texture has openings, and a total overlapping fineness of sinker loops in the lining texture, which is calculated by the following calculation formula, is 400 dtex to 1800 dtex.

[ Eq . 1 ] The total overlapping fineness of sinker loops ( dtex ) = K = 1 n ( The fineness of a ground yarn fed from a k th guide bar ( dtex ) ) ( The number of underlaps of the ground yarn fed from the k th guide bar ) ( The threading ratio of the k th guide bar )

Advantageous Effects of the Invention

The double raschel knitted fabric of the present invention is excellent in a strength although the outer texture has openings because the total overlapping fineness of sinker loops in the lining texture is 400 dtex to 1800 dtex.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view illustrating an opening in an outer texture;

FIG. 2 is a view for explaining the number of overlapping sinker loops in a case where the lining texture is composed of two denbigh knit textures;

FIG. 3 is a view for explaining the number of overlapping sinker loops in a case where the lining texture is composed of a denbigh knit texture and a cord knit texture with 2-needle swings;

FIG. 4 is a view for explaining the number of overlapping sinker loops in a case where the lining texture is composed of a denbigh knit texture and a cord knit texture with 3-needle swings;

FIG. 5 is a view for explaining the number of overlapping sinker loops in a case where the lining texture is composed of two denbigh knit textures and a cord knit texture with 3-needle swings, and underlap directions of the two denbigh knit textures are different;

FIG. 6 is a sectional view of a double raschel knitted fabric;

FIG. 7 is a view of a knitting portion of a double raschel knitting machine when viewed from the side (the same direction as the direction in which knitting needles are arranged);

FIG. 8 is a knitting chart of Example 1;

FIG. 9 is a knitting chart of Example 2;

FIG. 10 is a knitting chart of Example 3;

FIG. 11 is a knitting chart of Example 4;

FIG. 12 is a knitting chart of Example 5;

FIG. 13 is a knitting chart of Example 6;

FIG. 14 is a knitting chart of Example 7;

FIG. 15 is a knitting chart of Example 8;

FIG. 16 is a knitting chart of Example 9;

FIG. 17 is a knitting chart of Example 10;

FIG. 18 is a knitting chart of Comparative Example 1;

FIG. 19 is a knitting chart of Comparative Example 2;

FIG. 20 is a knitting chart of Comparative Example 3;

FIG. 21 is a knitting chart of Comparative Example 4;

FIG. 22 is a knitting chart of Comparative Example 5; and

FIG. 23 is a knitting chart of Comparative Example 6;

BEST MODE FOR CARRYING OUT THE INVENTION

A double raschel knitted fabric of the present invention will be described below. In addition, in the following descriptions, when a range is expressed as “(numerical value) to (numerical value),” the numerical values on both sides of the range shall be included in the range. In addition, in the following descriptions, in some cases, three of “A and B,” “A,” and “B” may be collectively expressed as “A and/or B.”

The double raschel knitted fabric is a kind of warp knitted fabric, and has outer/lining textures, that is, an outer texture and a lining texture. The double raschel knitted fabric further includes a joining portion that connects the outer texture to the lining texture. The joining portion is formed by joining yarns.

In the double raschel knitted fabric of the present invention, the outer texture has an opening. The opening is formed by a knitted texture, and passes through the outer texture in a direction perpendicular to the surface. The opening is formed at a place where adjacent loops are not connected in the knitting width direction such as, for example, a place indicated by the two-dot chain line of a symbol H in FIG. 1. In addition, FIG. 1 illustrates a knit texture by two guide bars, and in each of these two guide bars, yarns are arranged at 3in 3out. In FIG. 1, the solid line indicates a texture of yarns fed from one guide bar, and the broken line indicates a texture of yarns fed from the other guide bar. The knit, texture of the outer texture having an opening is, for example, a net texture or the like composed of yarns fed from two guide bars, but is not limited thereto. Specific configurations of the outer texture having the opening will be described below.

In addition, in the double raschel knitted fabric of the present invention, the total overlapping fineness of sinker loops in the lining texture is 400 dtex to 1800 dtex. Here, the total overlapping fineness of sinker loops in the lining texture is calculated by the following calculation formula.

[ Eq . 1 ] The total overlapping fineness of sinker loops ( dtex ) = K = 1 n ( The fineness of a ground yarn fed from a k th guide bar ( dtex ) ) ( The number of underlaps of the ground yarn fed from the k th guide bar ) ( The threading ratio of the k th guide bar )

In the calculation formula, the ground yarn refers to a yarn that forms the lining texture. In addition, the number of underlaps of the ground yarn is the number of underlaps of the ground yarn in the lining texture. In addition, the guide bar refers to a guide bar used for knitting the lining texture, and n is the number of guide bars used for knitting the lining texture. In addition, the threading ratio of the guide bar refers to a ratio of the number of guides through which yarns have passed to the number of all guides included in the guide bar. For example, in a case where yarns in a full set are fed to the guide bar, the threading ratio is 1.00, in a case where yarns are fed to the guide bar at 2in 2out or 3in 3out, the threading ratio is 0.50, in a case where yarns are fed to the guide bar at 3in 1out, the threading ratio is 0.75, and in a case where yarns are fed to the guide bar at 1in 3out, the threading ratio is 0.25.

According to the above calculation formula, for example, when the lining texture is composed of yarns fed from one guide bar,

the total overlapping fineness (dtex) of sinker loops

=the fineness (dtex) of a ground yarn×the number of under laps of the ground yarn×the threading ratio of the guide bar.

In addition, for example, when the lining texture is composed of yarns fed from two guide bars,

the total overlapping fineness (dtex) of sinker loops

=the fineness (dtex) of a ground yarn fed from a first guide bar

×the number of underlaps of the ground yarn fed from the first guide bar

×the threading ratio of the first guide bar

+the fineness (dtex) of a ground yarn fed from a second guide bar

×the number of underlaps of the ground yarn fed from the second guide bar

×the threading ratio of the second guide bar.

In addition, for example, when the lining texture is composed of yarns fed from three guide bars,

the total overlapping fineness (dtex) of sinker loops

=the fineness (dtex) of a ground yarn fed from a first guide bar

×the number of underlaps of the ground yarn fed from the first guide bar

×the threading ratio of the first guide bar

+the fineness (dtex) of a ground yarn fed from a second guide bar

×the number of underlaps of the ground yarn fed from the second guide bar

×the threading ratio of the second guide bar

+f the fineness (dtex) of a ground yarn fed from a third guide bar

×the number of underlaps of the ground yarn fed from the third guide bar

×the threading ratio of the third guide bar.

In the present invention, the fineness of a ground yarn in the lining texture, the number of underlaps of the ground yarn, and the number of guide bars used for knitting the lining texture are determined such that the total overlapping fineness of sinker loops in the lining texture falls within the above range. Specific configurations of the lining texture, which include the fineness and the like of the ground yarn, will be described below.

As described above, when the total overlapping fineness of sinker loops in the lining texture is 400 dtex to 1800 dtex, although the outer texture has openings, the double raschel knitted fabric is excellent in a strength. Here, as strengths which exhibit particularly excellent characteristics, a burst strength, a tensile strength, a tear strength and a seam fatigue may be mentioned.

When the total overlapping fineness of sinker loops in the lining texture is 400 dtex or more, the double raschel knitted fabric is excellent in the strengths as listed above. In addition, when the total overlapping fineness of sinker loops in the lining texture is 1800 dtex or less, the flexibility or the elongation characteristic of the double raschel knitted fabric is secured, and as a result, the workability such as a sewing property or a ease of tensioning on the sheet becomes good.

The total overlapping fineness of sinker loops in the lining texture is more preferably 500 dtex to 1600 dtex.

Accordingly, the above effects of the double raschel knitted fabric become more excellent.

The total overlapping fineness of sinker loops in the outer texture is also calculated by the above calculation formula. In calculating the total overlapping fineness of sinker loops in the outer texture by using the above calculation formula, the ground yarn refers to a yarn that forms the outer texture, the number of underlaps of the ground yarn is the number of underlaps of the ground yarn in the outer texture, and the guide bar refers to a guide bar used for knitting the outer texture.

Then, the sum of the total overlapping fineness of sinker loops in the outer texture, and the total overlapping fineness of sinker loops in the lining texture (hereinafter, “sum of the total overlapping finenesses of sinker loops in the outer/lining textures”) is preferably 650 dtex to 2000 dtex. When the sum of the total overlapping finenesses of sinker loops in the outer/lining textures is 650 dtex or more, the double raschel knitted fabric is excellent in the strengths as listed above. In addition, when the sum of the total overlapping finenesses of sinker loops in the outer/lining textures is 2000 dtex or less, the flexibility or the elongation characteristic of the double raschel knitted fabric is secured, and as a result, the workability such as the sewing property or the ease of tensioning on the sheet becomes good.

In addition, the sum of the total overlapping finenesses of sinker loops in the outer/lining textures is more preferably 650 dtex to 1700 dtex, and further preferably 750 dtex to 1600 dtex. When the sum of the total overlapping finenesses of sinker loops in the outer/lining textures is 650 dtex to 1700 dtex, the strength, the flexibility, and the elongation characteristic of the double raschel knitted fabric are satisfactorily compatible. In addition, when the sum of the total overlapping finenesses of sinker loops in the outer/lining textures is 750 dtex to 1600 dtex, the strength, the flexibility, and the elongation characteristic of the double raschel knitted fabric are more satisfactorily compatible.

Here, the fineness of a line of thread used for the double raschel knitted fabric of the present invention is preferably 84 dtex to 550 dtex. When the fineness of the line of thread is 84 dtex or more, the double raschel knitted fabric is excellent in a strength. In addition, when the fineness of the line of thread is 550 dtex or less, the flexibility of the double raschel knitted fabric becomes good, and the workability such as a sewing property becomes good. In addition, the material, the shape, and the like of the line of thread used for the double raschel knitted fabric are not particularly limited.

Here, the single fineness of the line of thread used for the double raschel knitted fabric of the present invention (also called a single fiber fineness) is preferably 2.3 dtex to 8.3 dtex, and more preferably 2.3 dtex to 4.6 dtex. When the single fineness of the line of thread is 2.3 dtex or more, the double raschel knitted fabric is excellent in a strength. In addition, when the single fineness of the line of thread is 3.3 dtex or less, the flexibility of the double raschel knitted fabric becomes good, and the workability such as a sewing property becomes good. In particular, in the outer texture, when the ratio of the line of threads with the above single fineness (that is, 2.3 dtex to 3.3 dtex or 2.3 dtex to 4.6 dtex) included in the entire ground texture (that is, the ratio of the number of the line of threads with the above single fineness, to the number of all line of threads used for the outer texture) is 70% or more, a good texture double raschel knitted fabric may be obtained.

In addition, when monofilament yarns and multifilament yarns are used for the double raschel knitted fabric of the present invention, the ratio of the number of monofilament. yarns to the number of all yarns used for the double raschel knitted fabric is preferably 8% to 40%, and more preferably 8% to 30%. When the ratio of the number of monofilament yarns is 8% or more, the double raschel knitted fabric is excellent in a shape retention or a strength. In addition, when the ratio of the number of monofilament yarns is 40% or less, the flexibility of the double raschel knitted fabric becomes good, and the workability such as a sewing property becomes good.

Next, descriptions will be made on a preferred specific configuration of outer/lining textures in the double raschel knitted fabric of the present invention.

First, in the double raschel knitted fabric of the present invention, it is preferable that the lining texture is composed of a plurality of knit textures. That is, it is preferable that the lining texture is composed of yarns fed from a plurality of guide bars, and the yarns fed from the guide bars form different knit textures, respectively.

In a case where the lining texture is composed of a plurality of knit textures, when underlap directions of these knit, textures are different, or when the numbers of under laps of these knit textures are different, sinker loops of these knit textures overlap each other as illustrated in FIG. 2 to FIG. 5. In addition, in the drawings, F indicates a knitting course with knitting needles on the front side (outer side), and B indicates a knitting course with knitting needles on the back side (lining side).

For example, as in FIG. 2, the lining texture is composed of two knit textures, in which one of these is a denbigh knit texture indicated by the broken line, the other is a denbigh knit texture indicated by the solid line, and underlap directions of these two denbigh knit textures shall be different. In this case, as in FIG. 2, sinker loops intersect and overlap each other. In FIG. 2, the number of overlapping sinker loops in the lining texture is two.

Here, the number of overlapping sinker loops in the lining texture refers to the number of sinker loops overlapping within one wale and one course in the lining texture (that is, within a range surrounded by two stitches adjacent in the wale direction and two stitches adjacent in the course direction in the lining texture, that is, within the range surrounded by the two-dot chain line in FIG. 2 to FIG. 5).

The number of overlapping sinker loops in the lining texture varies according to the number of underlaps in a knit texture constituting the lining texture, the number of knit textures constituting the lining texture (that is, the number of guide bars for knitting the lining texture), and the like.

For example, as illustrated in FIG. 3, when the lining texture is composed of a denbigh knit texture indicated by the broken line and a cord knit texture with 2-needle swings indicated by the solid line, the number of overlapping sinker loops in the lining texture is three. In addition, as illustrated in FIG. 4, when the lining texture is composed of a denbigh knit texture indicated by the broken line and a cord knit texture with 3-needle swings indicated by the solid line, the number of overlapping sinker loops in the lining texture is four. As illustrated in FIG. 5, when the lining texture is composed of a denbigh knit texture indicated by the broken line, a denbigh knit texture indicated by the one-dot chain line, and a cord knit texture with 3-needle swings indicated by the solid line, in a case where underlap directions of the two denbigh knit textures are different, the number of overlapping sinker loops in the lining texture is five.

In this manner, when the lining texture is composed of a plurality of knit textures and sinker loops overlap each other, the average value of the numbers of overlapping sinker loops in the lining texture is preferably 2 to 10 per wale course (2 to 10/(wale·course)).

Here, the average value of the numbers of overlapping sinker loops in the lining texture refers to a value obtained by calculating the numbers of overlapping sinker loops at all places within one pattern of the lining texture, obtaining an average of them, and rounding off the numbers after a decimal point. The reason the average is obtained in this manner is as follows. First, when all knit textures constituting the lining texture have arrangements of full-set yarns (that is, when knitted by guide bars in which full-set yarns are fed), the numbers of overlapping sinker loops are the same at any place in the lining texture. However, when at least one of knit textures constituting the lining texture has an arrangement in which some yarns are removed (that is, when knitted by guide bars in which some yarns are removed in feeding of yarns), the numbers of overlapping sinker loops in the lining texture vary according to places. This is because the average value of the numbers of overlapping sinker loops in the lining texture is related to the strength and the like of the double raschel knitted fabric.

When the average value of the numbers of overlapping sinker loops in the lining texture is 2 or more/(wale·course), the double raschel knitted fabric is excellent in a strength. Here, as strengths which exhibit particularly excellent characteristics, a burst strength, a tensile strength, a tear strength, and a seam fatigue may be mentioned. In addition, when the average value of the numbers of overlapping sinker loops in the lining texture is 10 or less/(wale·course), the flexibility or the elongation characteristic of the double raschel knitted fabric is secured, and as a result, the workability such as the sewing property or the ease of tensioning on the sheet becomes good.

The average value of the numbers of overlapping sinker loops in the lining texture is more preferably 3 to 7/(wale·course). Accordingly, the above effects of the double raschel knitted fabric become more excellent.

In addition, when the outer texture is composed of a plurality of knit textures, and sinker loops of these knit textures overlap each other, it is possible to obtain the average value of the numbers of overlapping sinker loops in the outer texture in the same manner as for the lining texture. Then, when sinker loops of the plurality of knit textures overlap each other in each of the outer texture and the lining texture, the sum of the average value of the numbers of overlapping sinker loops in the outer texture and the average value of the numbers of overlapping sinker loops in the lining texture is preferably 4 to 15/(wale·course).

When the sum of the average value of the numbers of overlapping sinker loops in the outer texture and the average value of the numbers of overlapping sinker loops in the lining texture is 4 or more/(wale·course), the double raschel knitted fabric is excellent in a strength. Here, as strengths which exhibit particularly excellent characteristics, a burst strength, a tensile strength, a tear strength, and a seam fatigue may be mentioned. In addition, when the sum is 15 or less/(wale-course), the flexibility or the elongation characteristic of the double raschel knitted fabric is secured, and as a result, the workability such as the sewing property or the ease of tensioning on the sheet becomes good.

The sum of the average value of the numbers of overlapping sinker loops in the outer texture and the average value of the numbers of overlapping sinker loops in the lining texture is more preferably 6 to 11/(wale·course). Accordingly, the above effects of the double raschel knitted fabric become more excellent.

Next, descriptions will be made on a case where the lining texture has a cord knit texture. When the lining texture is composed of a plurality of knit, textures, it is preferable that at least one of the plurality of knit textures is a cord knit texture. Accordingly, the number of underlaps of the cord knit texture may be adjusted so that the total overlapping fineness of sinker loops in the lining texture may fall within a desired range.

In addition, when at least one of the plurality of knit textures of the lining texture is the cord knit texture, it is preferable that the remaining knit textures of the lining texture are a denbigh knit texture and/or a chain knit texture. That is, it is preferable that the lining texture has a combination of a cord knit texture and a denbigh knit texture, a combination of a cord knit texture and a chain knit texture, or a combination of a cord knit texture, a denbigh knit texture, and a chain knit texture. When the lining texture has these combinations, the double raschel knitted fabric is excellent in an elongation balance in each direction. In addition, the lining texture may have a combination of one cord knit texture, one denbigh knit texture and/or one chain knit texture. In addition, the lining texture may have a combination of a plurality of cord knit textures, one denbigh knit texture and/or one chain knit texture.

In this manner, when the lining texture is composed of a combination of a cord knit texture and one or more of a denbigh knit texture and a chain knit texture, needle loops of the cord knit texture, and needle loops of the denbigh knit texture and/or the chain knit texture may overlap in different directions. That is, when the lining texture has a combination of a cord knit texture and a denbigh knit texture, needle loops of these two textures may overlap in different directions, when the lining texture has a combination of a cord knit texture and a chain knit texture, needle loops of these two textures may overlap in different directions, and when the lining texture has a combination of a cord knit texture, a denbigh knit texture, and a chain knit texture, needle loops of the cord knit texture may overlap needle loops of the other two knit textures in different directions. Accordingly, the ground yarn of the cord knit texture and the ground yarn(s) of the denbigh knit texture and/or the chain knit texture are pulled in the opposite direction to the wale direction at positions of needle loops, and the needle loops become large. As a result, an elastic property of the double raschel knitted fabric is improved.

In addition, when the lining texture has a combination of at least a cord knit texture and a denbigh knit texture, it is preferable that the cord knit texture and the denbigh knit texture form sinker loops through under lapping in the same direction. Accordingly, the elongation of the double raschel knitted fabric in the knitting direction becomes good, knitting or processing of the double raschel knitted fabric becomes easy, and the double raschel knitted fabric is less likely to wrinkle even when the ground yarns contract.

In addition, when the lining texture has a combination of a cord knit texture and one or more of a denbigh knit texture and a chain knit texture, it is preferable that needle loops formed by the cord knit texture are closed-stitches. Accordingly, the shape of the needle loops becomes large. When the shape of the needle loops becomes large, the elongation balance of the knitting direction and the knitting width direction of the double raschel knitted fabric becomes good. In addition, since the needle loops become flexible, the double raschel knitted fabric is less likely to wrinkle.

In addition, when the lining texture has a combination of a cord knit texture and one or more of a denbigh knit texture and a chain knit texture, it is preferable that needle loops formed by the denbigh knit texture and/or the chain knit texture are opened-stitches. Accordingly, the yarn lengths of ground yarns that form the denbigh knit texture and/or the chain knit texture become short, and the elongation of the double raschel knitted fabric in the knitting width direction is suppressed so that the elongation balance is improved.

In addition, when the lining texture has a combination of a cord knit texture and one or more of a denbigh knit texture and a chain knit texture, it is preferable that the cord knit texture is arranged on the needle loop side of the lining texture, and the denbigh knit texture and/or the chain knit texture are/is arranged on the sinker loop side of the lining texture. In general, the cord knit texture is a texture having a good elongation. Meanwhile, through the above arrangement, sinker loops of the cord knit texture are suppressed by the denbigh knit texture so that the elongation of the knitting direction and the knitting width direction may be suppressed.

As described above, when the cord knit texture is arranged on the needle loop side of the lining texture, and the denbigh knit texture and/or the chain knit texture are/is arranged on the sinker loop side of the lining texture, the denbigh knit texture and/or the chain knit texture on the sinker loop side have/has a greater influence on the elongation of the double raschel knitted fabric in the knitting direction. Therefore, in this case, when needle loops formed by the denbigh knit texture and/or the chain knit texture on the sinker loop side are opened-stitches, the above effects that the elongation of the double raschel knitted fabric in the knitting direction is suppressed and the elongation balance is improved become remarkable. Thus, this is particularly preferable.

So far, descriptions have been made on a case where the lining texture is composed of a plurality of knit textures, but the lining texture may be formed by only one knit texture. For example, the lining texture may be formed by one cord knit texture.

When the lining texture has a cord knit texture, the cord knit texture is preferably made with 2- to 8-needle swings regardless of the number of knit textures included in the lining texture. Accordingly, it becomes easy to set the total overlapping fineness of sinker loops of the lining texture within a desired range. In addition, when the cord knit texture is made with swings of two or more needles, the double raschel knitted fabric is excellent in a strength. In addition, when the cord knit texture is made with swings of eight or less needles, the flexibility or the elongation characteristic of the double raschel knitted fabric is secured, and as a result, the workability such as the sewing property or the ease of tensioning on the sheet becomes good.

When the lining texture has a cord knit texture, the cord knit texture is particularly preferably made with 3- to 6-needle swings. Accordingly, the above effects of the double raschel knitted fabric become more excellent.

Regardless of specific configurations of the outer/lining textures, an angle formed between the outer/lining textures and the joining yarn is preferably 30° to 85° in a state where no stress is applied to the double raschel knitted fabric. As illustrated in FIG. 6, the angle formed between the outer/lining textures and the joining yarn is an angle θ formed between outer/lining textures 1 and 2 and a joining yarn 4 (an angle at a place where the angle is the smallest). In a case where the angle formed between the outer/lining textures and the joining yarn is 30° or more, even when a force in the thickness direction is applied to the double raschel knitted fabric, the double raschel knitted fabric is hardly crushed and then the thickness is maintained. In addition, in a case where the angle formed between the outer/lining textures and the joining yarn is 85° or less, even when tension is applied to the outer/lining textures in the knitting direction and the knitting width direction, the joining yarn is not largely displaced and then the double raschel knitted fabric is hardly deformed.

Although the angle formed between the outer/lining textures and the joining yarn varies according to joining yarns, the ratio of joining yarns (the ratio of the number of joining yarns) in which the angle formed between the outer/lining textures and the joining yarn is 30° to 85°, is preferably 75% or less in ail joining yarns.

In addition, the angle formed between the outer/lining textures and the joining yarn is more preferably 40° to 85°. In addition, the ratio of joining yarns (the ratio of the number of joining yarns) in which the angle formed between the outer/lining textures and the joining yarn is 40° to 85°, is more preferably 75% or less in all joining yarns. Accordingly, the above effect that the double raschel knitted fabric is hardly crushed becomes more excellent.

In addition, regardless of specific configurations of the outer/lining textures, the density of the double raschel knitted fabric is preferably 18 to 60 courses/25.4 mm and 16 to 50 wales/25.4 mm. When the density is equal to or higher than these lower limit values, the flexibility or the workability of the double raschel knitted fabric becomes good. When the density is equal to or lower than these upper limit values, the elongation characteristic becomes good.

In addition, regardless of specific configurations of the outer/lining textures, the thickness of the double raschel knitted fabric is preferably 2 mm to 12 mm. When the thickness is 2 mm or more, the seam fatigue or the burst strength of the double raschel knitted fabric becomes good. In addition, when the thickness is 12 mm or less, the flexibility or the workability of the double raschel knitted fabric becomes good.

In addition, the thickness of the double raschel knitted fabric is more preferably 2 mm to 8 mm. When the thickness is 8 mm or less, the flexibility or the workability of the double raschel knitted fabric becomes better.

In addition, regardless of specific configurations of the outer/lining textures, the burst strength of the double raschel knitted fabric is 1800 Pa to 3800 Pa. Here, the burst strength refers to a burst strength measured by a method of Example to be described below. When the burst strength is 1800 Pa or more, it is possible to obtain a durability sufficient for applications such as vehicle interior materials, interior materials, or shoes. In addition, when the burst strength is 3800 Pa or less, the texture is hardly hardened, and is less likely to wrinkle.

The burst strength of the double raschel knitted fabric is more preferably 1900 Pa to 3200 Pa. Accordingly, the durability, the texture, and the like become better.

In addition, regardless of specific configurations of the outer/lining textures, The seam fatigue of the double raschel knitted fabric is preferably 2.5 mm or less. Here, the seam fatigue refers to a seam fatigue measured by a method of Example to be described below. When the seam fatigue is 2.5 mm or less, ground yarns are hardly broken from the seam and the double raschel knitted fabric is hardly torn. Thus, the durability of the double raschel knitted fabric becomes good.

The above described double raschel knitted fabric is knitted by a double raschel knitting machine which is a kind of warp knitting machine. As illustrated in FIG. 7, the double raschel knitting machine includes two knitting needle rows N1 and N2, guide bars L1 to L6 which include a plurality of guides G1 to G6, respectively (which may be expressed as L-1 to L-6, in the drawing), and beams B1 to B6 that supply yarns to the guide bars L1 to L6, respectively. In FIG. 7, reference numerals M1 and M2 indicate needle hooks.

The gauge of the double raschel knitting machine is preferably 14 to 28. When the gauge of the double raschel knitting machine is 14 or more, the texture of the knitted double raschel knitted fabric is hardly hardened, and a weight of the double raschel knitted fabric is hardly got heavy so that, the workability is less likely to be impaired. In addition when the gauge of the double raschel knitting machine is 28 or less, the texture of the knitted double raschel knitted fabric is hardly hardened, and the elongation of the double raschel knitted fabric is good so that wrinkle or deformation is less likely to occur during the use.

By such a double raschel knitting machine, the double raschel knitted fabric of the present invention is knitted. When the double raschel knitting machine is operated, knitting yarns A1 to A6 supplied from the beams B1 to B6 are knitted into a double raschel knitted fabric 10 composed of the outer texture 1, the lining texture 2, and a joining portion 3 by an operation of the guide bars L1 to L6 and the knitting needle rows N1 and N2.

A conventionally known post-processing, for example, dyeing, heat-setting, or the like may be performed on the double raschel knitted fabric knitted by the double raschel knitting machine.

The manufactured double raschel knitted fabric of the present invention is used as, for example, interior materials, vehicle interior materials, or shoes. As for the vehicle interior materials, for example, a seat surface of a seat, a backrest, and a headrest may be exemplified. The double raschel knitted fabric of the present invention has not only an excellent texture or cushioning, but also openings in the outer texture, and thus is good in a breathability and also good in a comfort at the time of sweating. Then, as described above, the double raschel knitted fabric of the present invention is also excellent in a strength. Therefore, the double raschel knitted fabric of the present invention is suitable for at least the above applications.

Next, Examples and Comparative Examples will be described.

EXAMPLE 1

A double raschel knitted fabric was knitted by using a 22-gauge double raschel knitting machine (RD6DPLM-77E-22G manufactured by Karl Mayer). As illustrated in FIG. 3, polyester multifilament yarns of 167 dtex/43f, in a full set, were arranged in a guide bar L-1 to form a cord knit texture (1-0/3-4) with 3-needle swings, and polyester multifilament yarns of 167 dtex/48f, in a full set, were arranged in a guide bar L-2 to form a denbigh knit texture (0-1/2-1), so that a lining texture was knitted. In addition, polyester monofilament yarns of 33 dtex/1f, in a full set, were arranged in a guide bar L-3 to connect outer/lining textures to each other. In addition, polyester textured yarns of 167 dtex/48f were arranged at 3in 3out in a guide bar L-4, and polyester textured yarns of 167 dtex/43f were arranged at 3in 3out in a guide bar L-5 so as to knit the outer texture.

The knitted double raschel knitted fabric was subjected to pre-setting by a heat setter at 190° C. for 1 min, was dyed with disperse dye at 130° C., was dried, and was subjected to finish-setting by the heat setter at 150° C. for 1 min. Then, the finished double raschel knitted fabric (34 courses/25.4 mm, 23 wales/25.4 mm, thickness 3.0 mm) was obtained. The properties of the obtained double raschel knitted fabric, and the composition of the knitted fabric are noted in Table 1.

EXAMPLES 2 AND 10 AND COMPARATIVE EXAMPLES 1 TO 6

Double raschel knitted fabrics in Examples 2 to 10 and Comparative Examples 1 to 6 are summarised in FIG. 9 to FIG. 23 and Table 1 to Table 2. Unless otherwise specified, methods for manufacturing the double raschel knitted fabrics in Examples 2 to 10 and Comparative Examples 1 to 6 are the same as that in Example 1.

Next, evaluation items and evaluation methods of the double raschel knitted fabrics in Examples and Comparative Examples will be described.

[Seam Fatigue]

Two knitted fabric pieces each of which has a width of 100 mm, and a length of 100 mm were collected as one set from each of the knitting direction and the knitting width direction Then, the front sides of the two knitted fabric pieces were matched, and sewing was performed at a position 7 mm from the end of one side to obtain a test piece. The sewing conditions were as follows: knitting needle: DP×17 21BPD (Manufactured by Organ Needle Co., Ltd.), sewing thread: polyester #8, seam type: lockstitch, and seam pitch: 5.0±0.5 mm. In addition, two cutting lines were formed in each of two sides parallel to the sewing machine seam of the test piece. The cutting lines were formed at positions 25 mm inside from both ends of the side parallel to the sewing machine seam. The length of the cutting line was set to 83 mm. Two sets of these test pieces were made from each of the knitting direction and the knitting width direction.

By using an Amsler type seam fatigue tester (ATD-200L, manufactured by Daiei Kagaku Seiki Co., Ltd.), the test piece was gripped at an interval of 120 mm, at the central part among three parts divided by the two cutting lines, and a load of 30N was applied to each of both sides. A test was performed on 2500 reciprocations under the conditions of a stroke of 150 mm and a speed of 30 reciprocations/min. After the reciprocation test, in a state where the load was applied, the maximum value of a dimension of a hole caused by a deviation of a seam of the test piece was measured.

The seam fatigue was represented by 3 larger one of values of the two sets of test pieces for each of the knitting direction and the knitting width direction. When the result is 2.5 mm or less, it can be said that the seam fatigue is excellent.

[Burst Strength]

A tensile testing machine for fabric, which was equipped with a push rod-type bursting jig having a diameter of 25 mm (TGE-10 kN, manufactured by MinebeaMitsumi Co., Ltd.), was used. A push rod was pushed into a circular test piece with a diameter of 44 mm, which was collected from the double raschel knitted fabric at a speed of 100 mm/min, and the maximum point m of the test force at that time was converted to Pa to obtain a burst strength.

[Tensile Strength-Elongation Rate]

Three test pieces each of which has a. width of 50 mm and length of 250 mm were collected from each of the knitting direction and the knitting width direction, and reference lines were marked on these test pieces such that a distance between the reference lines was 100 mm. Then, the test piece was attached to a gripping tool of an Instron type testing machine at a gripping interval of 150 mm, and an initial load of 1.0 N was applied, so that wrinkle or sagging was removed. The test piece was pulled at a speed of 200 mm/min, and the maximum load, and a distance between the reference lines at breakage were measured.

The average value of maximum loads of the three test pieces for each of the knitting direction and the knitting width direction was set as a tensile strength. When the result is 392 N/50 mm or more, it can be said that the tensile strength is excellent.

An elongation rate was calculated by the following equation, and was expressed by an average value of the three test pieces.


elongation rate={(L1−L0)/L0}×100

L0: distance between reference lines under initial loading (mm)

L1: distance between reference lines at breakage (mm)

[Tear Strength]

Three test pieces each of which has a width of 50 mm and a length of 250 mm were collected from each of the knitting direction and the knitting width direction. Then, a 10 mm cutting line was formed at a right angle to the side of the test, piece, at the center of the test piece in the length direction, and an isosceles trapezoid mark with a short side of 100 mm and a long side of 150 mm was marked such that the cutting line was placed on the center of the short side of the isosceles trapezoid. Then, parts on both hypotenuse sides of the isosceles trapezoid described on the test piece were attached to a gripping tool of an Instron type testing machine, at a gripping interval of 100 mm. Here, the attachment was performed such that the short side of the trapezoid was pulled and the long side was loosen. Then, the test piece was torn at a speed of 200 mm/min until cut, and then the maximum load was measured. The average values of maximum loads were obtained for the three test pieces in the knitting direction and the three test pieces in the knitting width direction, respectively, and the average values were set as tear strengths of the knitting direction and the knitting width direction, respectively. When the result is 78.4 N or more, it can be said that the tear strength is excellent.

Evaluation results of the double raschel knitted fabrics in Examples and Comparative Examples are as noted in Table 3 and Table 4. It was found that the evaluation results in Examples are good.

TABLE 1 Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Example 9 Example 10 Knitting L-1 Fineness (dtex) 167 110 167 187 167 167 280 330 167 110 Specifica- Number of 48 48 48 48 48 48 48 96 48 48 tions cord cord cord cord cord cord cord cord cord cord (3needles) (3needles) (5needles) (5needles) (3needles) (2needles) (5needles) (4needles) (4needles) (3needles) Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-2 Fineness (dtex) 167 110 167 167 167 167 167 330 167 110 Number of 48 48 48 48 48 48 48 96 48 48 denbigh denbigh denbigh cord denbigh denbigh denbigh denbigh chain denbigh (2needles) Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-3 Fineness (dtex) 33 33 33 167 33 33 33 56 33 33 Number of F 1 1 1 48 1 1 1 1 1 1 denbigh Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-4 Fineness (dtex) 167 167 167 33 167 167 167 220 110 110 Number of 48 48 48 1 48 48 48 96 48 48 Arrangement 3in3out 3in3out 3in3out FULLSET 2in2out 2in2out 3in3out 2in2out 3in3out 2in2out L-5 Fineness (dtex) 167 167 167 167 167 167 167 220 110 110 Number of ments 48 48 48 48 48 48 48 96 48 48 Arrangement 3in3out 3in3out 3in3out 2in2out 2in2out 2in2out 3in3out 2in2out 3in3out 2in2out L-6 Fineness (dtex) 167 Number of aments 48 Arrangement 2in2out Number of underlaps of cord knitted structure 3 3 5 5.2 3 2 5 4 4 3 Number of  of 1 1 1 1 1 1 1 1 0 1 Needle loops formed by denbigh opened- opened- opened- opened- opened- opened- opened- opened- opened- opened- stitch stitch stitch stitch stitch stitch stitch stitch stitch stitch Needle loops formed by cord knitted closed- closed- closed- closed- closed- closed- closed- closed- closed- closed- stitch stitch stitch stitch stitch stitch stitch stitch stitch stitch Number of guide 2 2 2 3 2 2 2 2 2 2 Overlapping  of cord and overlapping  of  and/or chain different different different different different different different different different different directions directions directions directions directions directions directions directions directions directions Underlapping d  of cord and denbigh same same same same same same same same same same direction direction direction direction direction direction direction direction direction direction Knitted Thickness (mm) 3 3 3 4 3 3 3 4 3 3 Fabric Cou  desnity (cou /25.4 mm) 34 34 34 30 34 38 32 26 45 38 W  density ( /25.4 mm) 23 23 24 24 23 24 22 14 28 24 Angle (°) formed by joining y  and 45 85 60 85 50 45 45 30 45 80 Average value of numbers of overlapping  loops in  structure ( ) 4 4 6 8 4 3 6 5 4 4 Average value of numbers of overlapping  loops in  structure ( ) 3 3 3 2 2 2 3 2 3 2 Sum of average values of numbers of overlapping 7 7 9 10 6 5 9 7 7 6 Total overlapping  of  loops in  (dtex) 668 440 1002 1336 668 501 1567 1650 668 440 Total overlapping  of  loops in  structure (dtex) 501 501 501 334 334 334 501 440 330 220 Sum of total overlapping nesses of  loops in  structure (dtex) 1169 941 1503 1670 1002 835 2068 2090 998 660 indicates data missing or illegible when filed

TABLE 2 Comp. Exp. 1 Comp. Exp. 2 Comp. Exp. 3 Comp. Exp. 4 Comp. Exp. 5 Comp. Exp. 6 Knitting L-1 Fineness (dtex) 110 110 56 56 84 330 Specifica- Number of aments 48 48 24 24 24 96 tions cord cord cord cord cord cord (2needles) (2needles) (3needles) (3needles) (2needles) (5needles) Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-2 Fineness (dtex) 110 110 56 56 84 220 Number of aments 48 48 24 24 24 48 denbigh denbigh denbigh denbigh denbigh denbigh Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-3 Fineness (dtex) 33 33 22 33 33 110 Number of aments 1 1 1 1 1 1 for 0 wales for 0 wales Arrangement FULLSET FULLSET FULLSET FULLSET FULLSET FULLSET L-4 Fineness (dtex) 167 167 84 56 84 330 Number of aments 48 48 24 24 24 96 Arrangement 3in3out 2in2out 2in2out 1in1out 1in1out 1in1out L-5 Fineness (dtex) 167 167 84 56 84 330 Number of aments 48 48 24 24 24 96 Arrangement 3in3out 2in2out 2in2out 1in1out 1in1out 1in1out L-6 Fineness (dtex) Number of aments Arrangement Number of underlaps of cord knitted structure 2 2 3 3 2 5 Number of underlaps of denbigh knitted structure 1 1 1 1 1 1 Needle loops formed by denbigh knitted structure and/or chain knitted structure opened- opened- closed- opened- closed- closed- stitch stitch stitch stitch stitch stitch Needle loops formed by cord knitted structure closed- opened- closed- closed- closed- closed- stitch stitch stitch stitch stitch stitch Number of guide  lining structure 2 2 2 2 2 2 Overlapping direction of cord and overlapping direction of denbigh and/or chain different different different different different same directions directions directions directions directions direction Underlapping directions of cord and denbigh same different different same different same direction directions directions direction directions direction Knitted Thickness (mm) 3 3.6 2 3 3.6 10 Fabric Course desnity (course/25.4 mm) 34 36 38 34 30 20 w  density (w /25.4 mm) 23 25 26 23 24 15 Angle (°) formed by joining y  and outer/lining structure 90 45 80 85 85 60 Average value of numbers of overlapping  loops in lining structure (number/ ) 3 3 4 4 3 6 Average value of numbers of overlapping  loops in outer structure (number/ ) 3 2 2 1 1 1 Sum of average values of numbers of overlapping  loops in outer/lining structures 6 5 6 5 4 7 Total overlapping neness of  loops in lining structure (dtex) 330 330 224 224 252 1870 Total overlapping neness of  loops in outer structure (dtex) 501 334 168 56 84 330 Sum of total overlapping nesses of  loops in outer/lining structure (dtex) 831 664 392 280 336 2200 indicates data missing or illegible when filed

TABLE 3 Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Evaluation Seam Fatigue the knitting direction 1.2 1.0 1.0 1.0 1.1 1.2 Results the knitting width direction 2.0 1.8 1.2 1.1 1.6 1.8 Burst Strength (Pa) 2536 1900 3277 3300 2100 1950 Tensile Strength (N/50 mm) the knitting direction 626 499 587 550 520 470 the knitting width direction 897 884 1615 1650 980 860 Tear Strength (N) the knitting direction 335 282 343 320 290 260 the knitting width direction 405 314 363 330 320 290 Elongation Rate (%) the knitting direction 52 45 58 60 45 45 the knitting width direction 50 58 48 50 62 58 Example 7 Example 8 Example 9 Example 10 Evaluation Seam Fatigue the knitting direction 1.0 1.1 1.6 1.8 Results the knitting width direction 1.1 1.1 1.4 1.6 Burst Strength (Pa) 3285 3410 2150 2060 Tensile Strength (N/50 mm) the knitting direction 590 550 530 480 the knitting width direction 1670 1690 850 850 Tear Strength (N) the knitting direction 350 365 270 420 the knitting width direction 335 350 260 440 Elongation Rate (%) the knitting direction 62 43 45 59 the knitting width direction 46 45 60 48

TABLE 4 Comp. Exp. 1 Comp. Exp. 2 Comp. Exp. 3 Evaluation Seam Fatigue the knitting direction 1.0 2.7 3.5 Results the knitting width direction 1.8 2.8 3.2 Burst Strength (Pa) 1650 1499 1013 Tensile Strength (N/50 mm) the knitting direction 554 480 640 the knitting width direction 608 570 680 Tear Strength (N) the knitting direction 238 280 320 the knitting width direction 286 310 370 Elongation Rate (%) the knitting direction 76 68 83 the knitting width direction 68 78 88 Comp. Exp. 4 Comp. Exp. 5 Comp. Exp. 6 Evaluation Seam Fatigue the knitting direction 3.8 3.4 1.2 Results the knitting width direction 3.7 3.3 1.1 Burst Strength (Pa) 870 960 3200 Tensile Strength (N/50 mm) the knitting direction 680 475 540 the knitting width direction 710 665 1560 Tear Strength (N) the knitting direction 330 270 360 the knitting width direction 390 305 330 Elongation Rate (%) the knitting direction 82 65 30 the knitting width direction 86 75 35

DESCRIPTION OF REFERENCE NUMERALS AND SIGNS

A1 to A6 . . . knitting yarns, B1 to B6 . . . beams, G1 to G6 . . . guides, H . . . opening, L1 to L6 . . . guide bars, M1 to M2 . . . needle hooks, N1 to N2 . . . knitting needle rows, 1 . . . outer texture, 2 . . . lining texture, 3 . . . joining portion, 4 . . . joining yarn, 10 . . . double raschel knitted fabric

Claims

1. A double raschel knitted fabric comprising an outer texture, a lining texture, and a joining portion connecting the outer texture and the lining texture, wherein the outer texture has openings, and a total overlapping fineness of sinker loops in the lining texture is 400 dtex to 1800 dtex, calculated by a calculation formula: ⁢ [ Eq. ⁢ 1 ] The ⁢ ⁢ total ⁢ ⁢ overlapping ⁢ ⁢ fineness ⁢ ⁢ of ⁢ ⁢ sinker ⁢ ⁢ loops ⁢ ⁢ ( dtex ) = ∑ K = 1 n ⁢ ⁢ ( The ⁢ ⁢ fineness ⁢ ⁢ of ⁢ ⁢ a ⁢ ⁢ ground ⁢ ⁢ yarn ⁢ ⁢ fed ⁢ ⁢ from ⁢ ⁢ a ⁢ ⁢ k th ⁢ ⁢ guide ⁢ ⁢ bar ⁢ ⁢ ( dtex ) ) ⁢ ( The ⁢ ⁢ number ⁢ ⁢ of ⁢ ⁢ underlaps ⁢ ⁢ of ⁢ ⁢ the ⁢ ⁢ ground ⁢ ⁢ yarn ⁢ ⁢ fed ⁢ ⁢ from ⁢ ⁢ the ⁢ ⁢ k th ⁢ ⁢ ⁢ guide ⁢ ⁢ bar ) ⁢ ( The ⁢ ⁢ threading ⁢ ⁢ ratio ⁢ ⁢ of ⁢ ⁢ the ⁢ ⁢ k th ⁢ ⁢ guide ⁢ ⁢ bar ).

2. The double raschel knitted fabric according to claim 1, wherein a sum of a total overlapping fineness of sinker loops in the outer texture and the total overlapping fineness of sinker loops in the lining texture is 650 dtex to 2000 dtex.

3. The double raschel knitted fabric according to claim 1, wherein the lining texture is composed of a plurality of knit textures, and an average value of numbers of overlapping sinker loops in the lining texture is 2 to 10 per wale course.

4. The double raschel knitted fabric according to claim 3, wherein the outer texture is composed of a plurality of knit textures, and a sum of an average value of numbers of overlapping sinker loops in the outer texture and the average value of the numbers of overlapping sinker loops in the lining texture is 4 to 15 per wale course.

5. The double raschel knitted fabric according to claim 1, wherein the lining texture is composed of a plurality of knit textures, and at least one of the corresponding knit textures is a cord knit texture.

6. The double raschel knitted fabric according to claim 5, wherein the lining texture has a combination of the cord knit texture and one or more of a denbigh knit texture and a chain knit texture.

7. The double raschel knitted fabric according to claim 5, wherein the cord knit texture that forms the lining texture is made with 2- to 8-needle swings.

8. The double raschel knitted fabric according to claim 6, wherein needle loops of the cord knit texture that forms the lining texture, and needle loops of the denbigh knit texture and/or the chain knit texture that form(s) the lining texture overlap in different directions to form the needle loops.

9. The double raschel knitted fabric according to claim 6, wherein the cord knit texture and the denbigh knit texture that form the lining texture form sinker loops through underlapping in a same direction.

10. The double raschel knitted fabric according to claim 6, wherein needle loops formed b′ the cord knit texture that forms the lining texture are closed-stitches.

11. The double raschel knitted fabric according to claim 6, wherein needle loops formed by the denbigh knit texture and/or the chain knit texture that form(s) the lining texture are opened-stitches.

12. The double raschel knitted fabric according to claim 1, wherein a burst strength is 1800 Pa to 3800 Pa.

13. The double raschel knitted fabric according to claim 1, wherein a seam fatigue is 2.5 mm or less.

Patent History
Publication number: 20210130993
Type: Application
Filed: Jun 15, 2018
Publication Date: May 6, 2021
Applicant: SEIREN CO., LTD. (Fukui-shi, Fukui)
Inventors: Noritaka Mizukami (Fukui-shi), Fumio Shirasaki (Fukui-shi)
Application Number: 16/606,860
Classifications
International Classification: D04B 21/14 (20060101);