Technical Field
[0001] The present invention relates to a knitted lace manufacturing method.
Background Art
[0002] In a knitted lace fabric disclosed in Japanese Examined Patent Publication
JP-A 63-52142 (1988 ), a thermal bonding yarn which is thermally soluble is knitted into a scallop portion.
By heating the knitted lace fabric after knitting, the thermal bonding yarn is molten.
The thermal bonding yarn bonds an overlapping portion between a base portion of a
picot yarn and another yarn and a portion in which the thermal bonding yarn is exposed
other than the overlapping portion is dissolved and removed. Thereby fray can be prevented
from being generated in the scallop portion of the knitted lace.
[0003] In a knitted lace fabric disclosed in Japanese Unexamined Patent Publication
JP-A 11-81073 (1999 ), a covering yarn is knitted into a scallop portion. The covering yarn is constituted
by a core yarn having a heat solubility and a covering yarn to be a thermoplastic
synthetic fiber yarn. By heating the knitted lace fabric after knitting, a part of
the core yarn in the covering yarn is molten so that a molten substance spreads from
the covering yarn. Then, the molten substance is caked to bond other adjacent yarns
to each other. Consequently, fray can be prevented from being generated in the scallop
portion of the knitted lace.
[0004] US 4 786 549 A discloses a warp knit Raschel fabric having unidirectional stretch characteristics
and ravel resistant laid-in elastic yarns. The fabric is produced by laying in two
sets of spandex yarns with a set of inelastic knitted yarns. The two sets of spandex
yarns cross one another at a multiplicity of contact points. The knitted fabric is
subjected to dry heat in a temperature range between 385 and 400 degrees Fahrenheit.
[0005] EP 0 228 203 A1 discloses a warp knitted lace fabric comprising a plurality of chain stitches and
a ground insertion yarn, pattern yarn and/or other yarn interconnecting said chain
stitches. Said plurality of chain stitches are made either as a whole or in part by
a heat bonding yarn comprising a lace knitting yarn carrying a low-melting thermoplastic
synthetic resin covering and said heat bonding yarn being thermally jointed to itself
of to other component yarns at intersections.
[0006] FR 2 591 620 A1 discloses a lace, wherein each weft yarn is associated with at least one heat fusible
yarn, wherein the fusion of the heat fusible yarn provides stiffening of the weft
yarn.
[0007] WO 2005/021852 A1 discloses a fabric blank, comprising a first yarn consisting of polyamide or polyester
or blends of any of these materials with cotton. A second yarn is included into at
least a portion of said fabric blank, said second yarn being polyether-based and thermally
bonded to said first yarn.
[0008] In the knitted lace fabrics described above, a thermal bonding yarn is knitted into
only the scallop portion. In this case, as to a knitted lace formed by heating a knitted
lace fabric, the fray is still generated easily in portions other than the scallop
portion. Further, after manufacturing the knitted lace, the thermal bonding yarn may
get dissociated from residual yarns. In this case, a bond of a plurality of yarns
by the thermal bonding yarn is broken, and fray may be generated from a dissociated
portion.
Disclosure of Invention
[0009] Accordingly, an object of the invention is to provide a knitted lace in which a yarn
is prevented from fraying, and a manufacturing method thereof.
[0010] The invention provides a method of manufacturing a knitted lace comprising:
a knitted fabric knitting step of knitting an elastic knitted fabric in such a manner
that while a chain stitch structure in which a plurality of loop-shaped portions are
formed is formed with a chain stitch yarn, a thermal bonding yarn having a lower melting
temperature than that of the chain stitch yarn is knitted into the chain stitch structure;
a heating step of heating the knitted fabric containing the thermal bonding yarn to
a temperature equal to or lower than the melting temperature of the chain stitch and
equal to or higher than the melting temperature of the thermal bonding yarn; and
a breaking step of applying a tension to the knitted fabric containing the thermal
bonding yarn, thereby breaking the molten thermal bonding yarn into a plurality of
portions.
[0011] According to the invention, a knitted lace fabric is heated to a temperature which
is lower than a melting temperature of a chain stitch yarn and is equal to or higher
than a melting temperature of a thermal bonding yarn so that a part of the thermal
bonding yarn is partially fused. A part of the fused portion sticks to the chain stitch
yarn. By carrying out caking in this state, the chain stitch yarn coming in contact
with the thermal bonding yarn can be prevented from being isolated from the thermal
bonding yarn in a knitted lace manufactured by using the knitted lace fabric. Furthermore,
the respective yarns coming in contact with the thermal bonding yarn can be bonded
to each other through the thermal bonding yarn. Consequently, a coupling state of
the respective yarns can be maintained so that fray of the yarns can be prevented.
[0012] At a breaking step, furthermore, a tension is applied to a knitted fabric containing
a thermal bonding yarn. At this time, an amount of extension of the knitted fabric
exceeds an extension limit of the thermal bonding yarn so that the thermal bonding
yarn is divided into a plurality of portions. The thermal bonding yarn subjected to
melting which sticks to a chain stitch yarn is divided into a plurality of portions
so that a fused portion in which the thermal bonding yarn is disposed at an interval
is formed on the chain stitch yarn. The fused portion sticking to the chain stitch
yarn acts as a resisting member against the fray of the chain stitch yarn. For example,
the fused portion penetrates through the loop-shaped portion of the chain stitch yarn
so that a further fray of the chain stitch yarn can be prevented.
[0013] According to the invention, it is possible to prevent fray of respective yarns in
a knitted lace manufactured by heating a knitted lace fabric. For example, it is possible
to prevent fray of yarns caused by a manufacturing process such as sewing or cutting
of the knitted lace and the fray of the yarn caused by a using state such as wearing
or washing. Thus, it is possible to enhance quality of the knitted lace fabric. Furthermore,
the chain stitch structure is achieved with yarns other than the thermal bonding yarn,
so that by using a yarn having a heat resistance as a chain stitch yarn, it is possible
to stabilize a configuration of the whole knitted lace.
[0014] Furthermore, in this invention, it is preferable that a knitting condition at the
knitted fabric knitting step and a heating condition at the heating step are set so
that an extension limiting amount ε1 of the whole knitted fabric excluding the thermal
bonding yarn subjected to the heating step is larger than an extension limiting amount
ε2 of the thermal bonding yarn subjected to the heating step.
[0015] According to the invention, a knitting condition at a knitted fabric knitting step
and a heating condition at a heating step are set so that an amount of extending and
contracting limit of the whole knitted fabric subjected to the heating step is larger
than an amount of extending limit of the thermal bonding yarn subjected to the heating
step. For example, a stretch yarn is knitted or a chain stitch yarn itself is caused
to be elastic so that an elastic knitted fabric is manufactured. By extending the
elastic knitted fabric more greatly than the amount of extending limit of the thermal
bonding yarn subjected to the heating step, it is possible to generate the breakage
of the thermal bonding yarn without breaking yarns other than the thermal bonding
yarn, for example, the chain stitch yarn. Thus, it is possible to hinder a strength
of the knitted lace fabric frombeing reduced, thereby preventing fray of the knitted
fabric.
[0016] Furthermore, in this invention, it is preferable that the heating step and the breaking
step are carried out at the same time.
[0017] According to the invention, the heating step and the breaking step are carried out
at the same time. Consequently, the heating step and the breaking step can be carried
out at one time so that a manufacturing period can be shortened. For example, at a
thermal setting step of arranging the knitted fabric into a predetermined shape, the
heating step and the breaking step can be carried out at the same time. In this case,
by simply carrying out the thermal setting step, it is possible to implement the melting
of the thermal bonding yarn and the breakage of the bonding yarn into a plurality
of portions in one step.
[0018] Furthermore, in this invention, it is preferable that the heating condition at the
heating step is set to melt the thermal bonding yarn and to prevent yarns other than
the thermal bonding yarn which are contained in the knitted fabric, from being fragile.
[0019] According to the invention, the thermal bonding yarn is molten on a heating condition
that the yarns other than the thermal bonding yarn are prevented from being fragile.
Consequently, it is possible to prevent fray and to suppress reduction in strength
of the knitted fabric.
[0020] Furthermore, in this invention, it is preferable that the heating condition at the
heating step is set to divide the thermal bonding yarn through melting.
[0021] According to the invention, the thermal bonding yarn is divided at the breaking step
and the heating condition is properly set so that the thermal bonding yarn is divided
also at the heating step. Consequently, it is possible to increase an amount of division
of the thermal bonding yarn and to form the fused portion serving as a resisting member
against the fray of the chain stitch yarn more reliably, and to prevent the fray of
the chain stitch yarn further reliably.
[0022] Furthermore, in this invention, it is preferable that a polyester-based thermoplastic
polyurethane elastic yarn of 10 deniers to 300 deniers is used as the thermal bonding
yarn and is heated at a heating temperature of 170°C to 195°C for 30 sec to 90 sec
at the knitted fabric knitting step.
[0023] According to the invention, a polyester based thermoplastic polyurethane elastic
yarn of 10 deniers to 300 deniers is used as the thermal bonding yarn and is heated
at 170°C to 195°C for 30 sec to 90 sec so that yarns other than the thermal bonding
yarn which are contained in the knitted fabric can be prevented from being fragile
and it is possible to divide the thermal bonding yarn by sufficiently melting the
thermal bonding yarn.
[0024] Furthermore, in this invention, it is preferable that an inserting yarn other than
the thermal bonding yarn is knitted at the knitted fabric knitting step, and in the
chain stitch portion, a first loop-shaped portion and a second loop-shaped portion
are alternately connected and arranged in a plurality of stages in a wale direction;
the second loop-shaped portion is inserted through the first loop-shaped portion in
an earlier stage in the wale direction of the second loop-shaped portion and is extended
toward a later stage in the wale direction, and the second loop-shaped port ion is
inserted through the first loop-shaped portion in the same stage in the wale direction
of the second loop-shaped portion and is connected to the first loop-shaped portion
in the later stage in the wale direction, whereby the second loop-shaped portion is
formed like a chain and is extended in the wale direction in the chain stitch portion;
and directions of insertion of the thermal bonding yarn and the other inserting yarn
between the first loop-shaped portion and the second loop-shaped portion are set to
be different from each other in a portion in which both the thermal bonding yarn and
the other inserting yarn are knitted.
[0025] According to the invention, directions in which the thermal bonding yarn and another
inserting yarn are inserted between the first loop-shaped portion and the second loop-shaped
portion are different from each other in the portion in which both the thermal bonding
yarn and the other inserting yarn are knitted. Consequently, it is possible to lessen
the amount of contact of the other inserting yarn and the thermal bonding yarn, to
easily cause the molten thermal bonding yarn to stick to the chain stitch yarn and
to readily form a fused portion in the chain stitch yarn. For example, the inserting
yarns other than the thermal bonding yarn may be a pattern yarn or a jacquard yarn
for forming a pattern on a knitted lace and a stretch yarn for causing the knitted
lace to be elastic.
[0026] Furthermore, in this invention, it is preferable that, at the knitted fabric knitting
step, an elastic stretch yarn is knitted in addition to the thermal bonding yarn in
an extending state; a first loop-shaped portion and a second loop-shaped portion are
alternately connected and arranged in a plurality of stages in a wale direction; the
second loop-shaped portion of interest is inserted through the first loop-shaped portion
in an earlier stage in the wale direction of the second loop-shaped portion and is
extended toward a later stage in the wale direction, and is inserted through the first
loop-shaped portion in the same stage in the wale direction of the second loop-shaped
portion and is connected to the first loop-shaped portion in the later stage in the
wale direction, whereby the second loop-shaped portion is formed like a chain and
is extended in the wale direction in the chain stitch portion; and directions of insertion
of the thermal bonding yarn and the stretch yarn between the first loop-shaped portion
and the second loop-shaped portion are set to be different from each other in a portion
in which both the thermal bonding yarn and the stretch yarn are knitted.
[0027] According to the invention, directions in which the thermal bonding yarn and the
stretch yarn are inserted between the first loop-shaped portion and the second loop-shaped
portion are different from each other in the portion in which both the thermal bonding
yarn and the stretch yarn are knitted. Consequently, it is possible to lessen the
amount of contact of the stretch yarn and the thermal bonding yarn, to easily cause
the molten thermal bonding yarn to stick to the chain stitch yarn and to readily form
a fused portion in the chain stitch yarn.
[0028] In addition, in the case in which the thermal bonding yarn has a higher dissociation
to the chain stitch yarn than the stretch yarn, the thermal bonding yarn is dissociated
from the chain stitch yarn more easily when the thermal bonding yarn sticks to both
the stretch yarn and the chain stitch yarn. In the invention, it is possible to prevent
the thermal bonding yarn from sticking to both the stretch yarn and the chain stitch
yarn. Therefore, it is possible to reduce a possibility that the thermal bonding yarn
might be dissociated from the chain stitch yarn and to cause the fused portion acting
as a resisting member against fray to easily remain in the chain stitch yarn.
[0029] According to the invention, the knitted lace fabric is heated so that a part of the
thermal bonding yarn contained in the knitted lace fabric is molten and binding of
each yarn can be strengthened. Accordingly, it is possible to prevent the fray of
the knitted lace formed by using the knitted lace fabric. By breaking the thermal
bonding yarn to form the fused portion, furthermore, it is possible to further prevent
the fray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Other and further objects, features, and advantages of the invention will be more
explicit from the following detailed description taken with reference to the drawings
wherein:
Fig. 1 is a view showing a knitting structure, schematically illustrating a part of
a knitted lace fabric according to a first embodiment of the invention;
Fig. 2 is a view showing a knitting structure, schematically illustrating a part of
a first precursor knitted fabric to be a precursor of the knitted lace fabric;
Fig. 3 is a view showing a knitting structure, schematically illustrating a first
precursor knitted fabric 20, in which yarns other than a chain stitch yarn and a thermal
bonding yarn are omitted;
Fig. 4 is a flowchart showing a manufacturing process of the knitted lace fabric according
to the embodiment;
Figs. 5A and 5B are views for explaining that a fused portion becomes a resistor against
fray;
Figs. 6A and 6B are views for explaining that the fused portion becomes the resistor
against the fray;
Fig. 7 is a flowchart showing other manufacturing process of the knitted lace fabric;
Fig. 8 is a knitting view for explaining a prevention of the fray of a second precursor
knitted fabric according to the embodiment;
Fig. 9 is a knitting view showing the knitted lace fabric according to a comparative
example;
Fig. 10 is a knitting view for explaining fray of the second precursor knitted fabric
according to the embodiment;
Fig. 11 is a knitting view showing the knitted lace fabric according to the comparative
example;
Fig. 12 is a side view showing a knitting portion of a raschel knitting machine for
knitting the first precursor knitted fabric according to the first embodiment;
Figs. 13A to 13E are cross sectional views schematically illustrated for explaining
movements of a kitting needle and a base guide bar in a chain stitch portion;
Figs. 14A to 14C are cross sectional views schematically illustrated for explaining
movements of a jacquard bar and a guide bar for thermal bonding yarn;
Figs. 15A and 15B are structural views schematically illustrating an S region in Fig.
3;
Fig. 16 is a flowchart showing a manufacturing procedure of a knitted lace product;
Fig. 17 is a view showing a knitting structure, schematically illustrating a part
of the first precursor knitted fabric according to a second embodiment of the invention;
Fig. 18 is a view showing a knitting structure, schematically illustrating a part
of the first precursor knitted fabric according to a third embodiment of the invention;
Fig. 19 is a view showing a knitting structure, schematically illustrating the first
precursor knitted fabric in which yarns other than a chain stitch yarn, a thermal
bonding yarn and a stretch yarn are omitted;
Fig. 20 is a view showing a knitting structure, schematically illustrating apart of
the first precursor knitted fabric according to a fourth embodiment of the invention;
Fig. 21 is a side view showing a knitting portion of a back jacquard raschel knitting
machine for knitting the first precursor knitted fabric according to the third and
the fourth embodiments;
Fig. 22 is a view showing a knitting structure, schematically illustrating a part
of the first precursor knitted fabric according to a fifth embodiment of the invention;
and
Fig. 23 is a side view showing the knitting portion of the back jacquard raschel knitting
machine for knitting the first precursor knitted fabric according to the fifth embodiment.
DETAILED DESCRIPTION
[0031] Now referring to the drawings, preferred embodiments of the invention are described
below.
[0032] Fig. 1 is a view showing a knitting structure, illustrating a part of a knitted lace
fabric 120 according to a first embodiment of the invention. Fig. 2 is a view showing
a knitting structure, illustrating a part of a first precursor knitted fabric 20 to
be a precursor of the knitted lace fabric 120. Fig. 3 is a view showing a knitting
structure, illustrating the first precursor knitted fabric 20 in which yarns other
than a chain stitch yarn 21 and a thermal bonding yarn 23 are omitted. These Figs.
1 to 3 are views showing a knitting structure, schematically illustrated for easy
understanding. In actual knitting structures of the knitted lace fabric 120 and the
first precursor knitted fabric 20,radii of curvature of a first loop-shaped portion
24 and a second loop-shaped portion 25 are small and yarns 21, 22 and 23 are very
close to each other or in contact with each other. In the invention, furthermore,
a knitted fabric formed with each of the yarns 21, 22, and 23 is referred to as the
first precursor knitted fabric 20. And what is formed by heating the first precursor
knitted fabric 20 is referred to as a second precursor knitted fabric. Furthermore,
a knitted fabric formed by breaking the thermal bonding yarn 23 included in the second
precursor knitted fabric into a plurality thereof is referred to as a knitted lace
fabric 120, and a product manufactured by use of the knitted lace fabric 120 is referred
to as a knitted lace. In this embodiment, the first precursor knitted fabric 20 becomes
a warp knitted fabric knitted with knitting yarns.
[0033] In the knitted lace fabric 120 and the first precursor knitted fabric 20, a plurality
of through holes are formed, and a lace pattern is formed by a shape and arrangement
of the through holes. In the knitted lace fabric 120 and the first precursor knitted
fabric 20, furthermore, there are pattern portions in which an amount of yarns disposed
on per unit area is small and ground portions in which the amount of yarns disposed
on per unit area is large and patterns are formed depending on shapes and arrangements
of the pattern portions and the ground portions. A knitted lace fabric having such
a pattern is used for underwear for women, for example.
[0034] As shown in Fig. 2, the first precursor knitted fabric 20 is constituted by including
the chain stitch yarn 21, the thermal bonding yarn 23 and the inserting yarn 22. The
chain stitch yarn 21 is referred to as a warp or a ground knitting yarn in some cases.
Furthermore, the inserting yarn 22 is referred to as a weft in some cases. The thermal
bonding yarn 23 has a lower melting temperature than the other yarn to be used as
the first precursor knitted fabric 20 and has a thermoplasticity.
[0035] Fig. 4 is a flowchart showing a process for manufacturing the knitted lace fabric
120 according to the embodiment. First of all, when a preparation for a knitted fabric
formation is completed, that is, a selection of each knitting yarn to be used for
a knitted lace, a determination of a pattern to be formed on the knitted lace and
a design of a knitted fabric for forming a desirable knitting structure are completed
at Step a0, the processing proceeds to Step a1 in which the knitted lace fabric 120
is started to be manufactured.
[0036] At the Step a1, there is carried out a knitted fabric knitting step of forming the
first precursor knitted fabric 20 to be a precursor of the knitted lace fabric 120
by using a knitting machine. The knitting machine knits the respective yarns 21 and
22 such as the thermal bonding yarn 23 into the chain stitch yarn 21, thereby knitting
the first precursor knitted fabric 20 shown in Fig. 2 in accordance with a knitting
order designed at the Step a0. Accordingly, the first precursor knitted fabric 20
forms a chain stitch structure in which a plurality of loop-shaped portions are formed
by the chain stitch yarn 21, and furthermore, the thermal bonding yarn 23 is knitted
into the chain stitch structure.
[0037] At least one of the yarns provided in the first precursor knitted fabric 20 is elastic.
More specifically, at least one of the chain stitch yarn 21, the thermal bonding yarn
23 and the other yarns is elastic. The knitting machine executes a knitting operation
in a state in which the elastic yarn is extended. The first precursor knitted fabric
20 shrinks after knitting by a restoring force of the yarn knitted in the extending
state and becomes elastic. When the knitting operation for the first precursor knitted
fabric 20 is completed, thus, the processing proceeds to Step a2.
[0038] At the Step a2, there is carried out a heating step of heating the first precursor
knitted fabric 20 formed at the Step a1 to a temperature which is equal to or lower
than a melting temperature of the chain stitch yarn 21 and is equal or higher than
that of the thermal bonding yarn 23. Consequently, there is formed a second precursor
knitted fabric in which a part of the thermal bonding yarn 23 is partially fused.
A part of the fused portion of the second precursor knitted fabric sticks to the chain
stitch yarn 21 and the inserting yarn 22. In this state, the thermal bonding yarn
23 is caked. Consequently, the chain stitch yarn 21 and the inserting yarn 22 which
are provided in contact with the thermal bonding yarn 23 can be prevented from being
released from the thermal bonding yarn 23. Furthermore, the respective yarns 21 and
22 to come in contact with the thermal bonding yarn 23 are bonded to each other through
the thermal bonding yarn 23. When the thermal bonding yarn 23 thus molten is caused
to stick to the other yarns 21 and 22, the processing proceeds to Step a3.
[0039] At the Step a3, there is carried out a breaking step of applying a tension to extend
the second precursor knitted fabric formed at the Step a2 and breaking the thermal
bonding yarn 23 subjected to the melting into a plurality of portions. In order to
apply the tension to the second precursor knitted fabric, an amount of extension ε3
of the second precursor knitted fabric exceeds an amount of extension ε1 of the thermal
bonding yarn 23 so that the thermal bonding yarn 23 is divided into a plurality of
portions. When the thermal bonding yarn 23 subjected to the melting is thus broken,
the knitted lace fabric 120 shown in Fig. 1 can be formed and the processing proceeds
to Step a4.
[0040] At the Step a4, the knitted lace fabric 120 thus formed is refined and a heat treatment
which is also referred to as a final heat set is then carried out to fix a configuration,
and the knitted lace fabric is used to manufacture a lace product after the Step a3.
Thus, the manufacture of the knitted lace fabric 120 is ended.
[0041] As shown in Figs. 1 and 2, the knitted lace fabric 120 according to the embodiment
is formed by dividing the thermal bonding yarn 23 molten and bonded to the respective
yarns as compared with the first precursor knitted fabric 20 obtained immediately
after the knitted fabric is completely formed. In other words, the thermal bonding
yarn 23 of the knitted lace fabric 120 is intermittently positioned in a wale direction
W.
[0042] The thermal bonding yarn 23 which is divided constitutes a plurality of fused portions
100 disposed at an interval in the wale direction W, respectively. Each of the fused
portions 100 sticks to the yarns 21 and 22 other than the thermal bonding yarn 23
at an interval, respectively. Each of the fused portions 100 is displaced with the
sticking yarn irrespective of the other fused portions 100.
[0043] As shown in Fig. 1, furthermore, the fused portion 100 sticks to a yarn other than
the thermal bonding yarn 23 in some cases and sticks to a plurality of yarns other
than the thermal bonding yarn 23 in the other cases. For example, one of the fused
portions 100 sticks to couple the chain stitch yarn 21 and the inserting yarn 22 in
some cases. Furthermore, one of the fused portions 100 sticks to couple two portions
of the chain stitch yarn 21 in some cases.
[0044] Portions of the yarns 21 and 22 other than the thermal bonding yarn 23 to which the
fused portion 100 sticks form a portion which is protruded from a surface of an exposed
portion in which the fused portion 100 is not present. In other words, the yarns 21
and 22 to which the thermal bonding yarn 23 sticks are provided with convex portions
which are caused by the sticking of the fused portion 100. Consequently, the fused
portion 100 sticking to the respective yarns 21 and 22 acts as a resisting member
against fray of the respective yarns 21 and 22.
[0045] Figs. 5A and 5B are views for explaining that the fused portion 100 acts as the resisting
member against the fray. Fig. 5A shows a state in which a breakage is generated in
a broken portion 21 A of the chain stitch yarn 21. Fig. 5B shows a state in which
the chain stitch yarn 21 is pulled from the broken portion 21A.
[0046] In the embodiment, when the chain stitch yarn 21 is pulled toward a later stage side
in the wale direction W by setting the broken portion 21 A to be a starting point
as shown in Fig. 5A, an adjacent portion to the broken portion 21A of the chain stitch
yarn 21 is sequentially drawn to pass through a first loop-shaped portion 24 on an
earlier stage side in the wale direction W in some cases. When a portion of the chain
stitch yarn 21 to which the fused portion 100 sticks reaches the first loop-shaped
portion 24 as shown in Fig. 5B, however, the fused portion 100 is caught on the first
loop-shaped portion 24. Thus, the fused portion 100 is caught on the first loop-shaped
portion 24 so that a resistance to the drawing operation for the chain stitch yarn
21 is generated and the chain stitch yarn 21 can be prevented from being further drawn.
Consequently, it is possible to hinder the progress of the fray of the chain stitch
yarn 21, thereby preventing the fray of the chain stitch yarn 21.
[0047] Furthermore, Fig. 5B shows a space 102 of the first loop-shaped portion 24 having
such a shape that the fused portion 100 can pass for easy understanding. However,
the actual space 102 of the first loop-shaped portion 24 is formed to be sufficiently
smaller than the fused portion 100. Accordingly, it is possible to achieve an advantage
that it is possible to prevent the fray from being caused by the catch-on of the fused
portion 100.
[0048] Figs. 6A and 6B are views for explaining that the fused portion 100 to be a protruded
molten sticking substance acts as the resisting member against the fray. Fig. 6A shows
a state in which the breakage is generated in another broken portion 21 B of the chain
stitch yarn 21. Fig. 6B shows a state in which the chain stitch yarn 21 is pulled
from the other broken portion 21 B.
[0049] In the embodiment, when the chain stitch yarn 21 is pulled toward the later stage
side in the wale direction W by setting the other broken portion 21 B to be a starting
point as shown in Fig. 6A, an adjacent portion to the other broken portion 21 B in
the chain stitch yarn 21 is sequentially drawn from the loop-shaped portion to pass
through the first loop-shaped portion 24 on the earlier stage side in the wale direction
W in some cases. When a portion of the chain stitch yarn 21 which sticks to the inserting
yarn 22 through the fused portion 100 reaches the first loop-shaped portion 24 as
shown in Fig. 6B, however, the inserting yarn 22 bonded to the chain stitch yarn 21
is caught on the first loop-shaped portion 24. Thus, the inserting yarn 22 is caught
on the first loop-shaped portion 24 so that a resistance to the drawing operation
for the chain stitch yarn 21 is generated and the chain stitch yarn 21 can be prevented
from being further drawn. Consequently, it is possible to hinder the progress of the
fray of the chain stitch yarn 21, thereby preventing the fray of the chain stitch
yarn 21. Furthermore, Fig. 6B shows a state in which a part of the inserting yarn
22 passes through the space 102 of the first loop-shaped portion 24. In some cases,
a part of a short fiber (a monofilament) constituting the inserting yarn 22 is drawn
and a residual short fiber is not drawn but the inserting yarn 22 is caught thereon.
Also in this case, it is possible to sufficiently achieve an advantage that the fray
can be prevented from being caused by the catch-on of the inserting yarn 22.
[0050] Also in the case in which the fused portion 100 and the inserting yarn 22 are released
from each other, furthermore, the fused portion 100 acts as a resisting member against
the fray in the same manner as in the cases shown in Figs. 5A and 5B when the fused
portion 100 sticks to the chain stitch yarn 21. Thus, it is possible to prevent the
fray of the chain stitch yarn 21.
[0051] According to the embodiment, thus, the thermal bonding yarn 23 sticking to the chain
stitch yarn 21 is positively divided to break an original shape of the thermal bonding
yarn 23 at the breaking step. Consequently, the fused portion 100 having the thermal
bonding yarn 23 disposed at an interval sticks to the chain stitch yarn 21. Thus,
the shape of the bonding yarn 23 is changed to form a concavo-convex portion on the
chain stitch yarn 21. In other words, a denier nonuniformity (a thickness nonuniformity)
is generated on the chain stitch yarn 21. The fused portion 100 acts as the resisting
member against the fray of the chain stitch yarn 21 so that the progress of the fray
of the chain stitch yarn 21 can be prevented. Furthermore, the thread-shaped thermal
bonding yarn 23 does not remain in the knitted lace fabric 120. Therefore, a pattern
is less influenced by the thermal bonding yarn 23 so that a sense of beauty can be
enhanced.
[0052] In the embodiment, furthermore, the knitting condition in the knitted fabric knitting
step and the heating condition at the heating step are set in such a manner that the
extension limiting amount ε1 of the whole second precursor knitted fabric excluding
the thermal bonding yarn 23 is larger than the extension limiting amount ε2 of the
thermal bonding yarn 23 obtained after the heating step (ε1 > ε2). For example, by
knitting a stretch yarn into the chain stitch yarn 21 in the extending state, causing
the chain stitch yarn itself to be elastic or forming a knitted structure which can
easily be stretched, the extension limiting amount ε1 of the whole second precursor
knitted fabric excluding the thermal bonding yarn 23 is increased.
[0053] On the other hand, by using the thermal bonding yarn 23 having a small fineness,
using the thermal bonding yarn 23 having a small extension limiting amount obtained
after the melting or implementing the thermal boning yarn 23 by a material to generate
a fragility after a dissolution, the extension limiting amount ε2 of the thermal bonding
yarn 23 obtained after the heating step is reduced.
[0054] By carrying out the setting, thus, an extension amount ε3 of the second precursor
knitted fabric to be extended at the breaking step is set to be larger than the extension
limiting amount ε2 of the thermal bonding yarn 23 and to be smaller than the extension
limiting amount ε1 of the whole second precursor knitted fabric excluding the thermal
bonding yarn 23 (ε2 < ε3 < ε1). Consequently, it is possible to break the thermal
bonding yarn 23 without breaking the yarns 21 and 22 other than the thermal bonding
yarn 23, for example, the chain stitch yarn 21. Thus, it is possible to hinder a strength
of the knitted lace fabric 120 from being reduced, thereby preventing the fray of
the knitted lace fabric 120.
[0055] Furthermore, the heating condition at the heating step is set in such a manner that
the thermal bonding yarn 23 is molten and the yarns other than the thermal bonding
yarn 23 which are contained in the knitted fabric are prevented from being fragile.
Furthermore, it is preferable that the heating condition at the heating step should
be set to divide the thermal bonding yarn 23 through melting. Also before the breaking
step, consequently, the thermal bonding yarn 23 divided into a plurality of portions
can be caused to stick to the respective yarns after the heating step. More specifically,
the thermal bonding yarn 23 may be molten partially or wholly. By melting the whole
thermal bonding yarn 23 to prevent a thread-like original shape from being maintained,
furthermore, it is possible to form a large fused portion 100, thereby preventing
the fray more reliably.
[0056] For the heating condition, a heating temperature and a heating time are set, for
example. The lowest melting temperature for melting the thermal bonding yarn 23 is
represented by B1 and a time required for softening when heating is carried out at
the lowest melting temperature is represented by D1. Furthermore, the lowest melting
temperature at which the yarns other than the thermal bonding yarn 23 are made fragile
is represented by B2 and a time required for softening when the heating is carried
out at the lowest melting temperature is represented by D2. In this case, in the embodiment,
B1 < B3 < B2 and D1 < D3 < D2 are set, wherein a heating temperature and a heating
time at the heating step are represented by B3 and D3 respectively.
[0057] In the embodiment, a polyester based thermoplastic polyurethane elastic yarn of 10
deniers to 300 deniers, and preferably 10 deniers to 50 deniers is used as the thermal
bonding yarn 23. Furthermore, a heat treatment is carried out at a heating temperature
which is equal to or higher than 170°C and is equal to or lower than 195°C for a heating
time which is equal to or longer than 30 sec and is equal to or shorter than 90 sec.
Consequently, the thermal bonding yarn 23 is molten and the residual yarns can be
prevented from being fragile. In addition, the thermal bonding yarn 23 can be divided
by the melting. Furthermore, it is preferable that the thermal boning yarn 23 should
be constituted by a material which is caked after the melting, thereby increasing
a fragility, that is, reducing a strength than before the melting.
[0058] For example, in the case in which the heating time is constant, a bonding force of
the molten thermal bonding yarn 23 and the residual yarns is reduced when the heating
temperature is set to be lower than 170°C. Furthermore, the yarn is not divided as
the bonding yarn but the bonding yarn itself remains so that the second precursor
knitted fabric is hardened. When the heating temperature exceeds 195°C, furthermore,
a residual material such as nylon causes a hot shortness. On the other hand, in the
embodiment, it is possible to eliminate the problems by setting the heating temperature
to be equal to or higher than 170°C and to be equal to or lower than 195°C as described
above.
[0059] When the fineness is excessively increased, furthermore, the thermal bonding yarn
23 is hard to break. When the fineness is excessively reduced, furthermore, the bonding
force is reduced and the fused portion 100 cannot be enlarged. On the other hand,
by setting the fineness of the thermal bonding yarn 23 to be equal to or higher than
10 deniers and to be equal to or lower than 300 deniers, it is possible to easily
carry out the breakage, and furthermore, tomaintain the bonding force and to enlarge
the fused portion 100. By further setting the fineness of the thermal bonding yarn
23 to be equal to or higher than 10 deniers and to be equal to or lower than 50 deniers,
it is possible to prevent the thermal bonding yarn 23 from being more conspicuous
than the pattern, thereby increasing the bonding force of the chain stitch yarn 21
and the thermal bonding yarn 23.
[0060] Table 1 shows a result of fray test for the knitted lace according to the embodiment
in which the thermal bonding yarn 23 is broken and a knitted lace according to a comparative
example in which the thermal bonding yarn 23 is not broken.
[Table 1]
|
|
|
Knitted lace according to embodiment |
Knitted lace according to comparative example |
Breaking state of yarn |
|
Broken |
Not broken |
Washing resistance test |
Number of washing times: 30 |
Fray of scallop portion |
□ (No abnormality) |
○ (Slight fray) |
Fray of lace cut surface |
○ (Slight fray) |
□ (Fray) |
Number of washing times: 50 |
Fray of |
|
|
scallop portion |
□ (No abnormality) |
○ (Slight fray) |
Fray of lace cut surface |
○ (Slight fray) |
□ (Fray) |
[0061] For the fray test, the washing operation was repetitively carried out by a washing
method defined in the JIS-L-0217 103 Laws and a test for checking whether fray is
generated on a lace was performed.
[0062] As shown in the Table 1, in the embodiment in which the thermal bonding yarn 23 is
broken, the degree of the fray is lower than that in the comparative example in which
the thermal bonding yarn 23 is not broken. For this reason, the knitted lace according
to the embodiment can be prevented from being frayed more greatly than in the comparative
example.
[0063] Furthermore, it is preferable that the thermal bonding yarn 23 should be formed by
polyurethane elastic yarns manufactured by a melting spinning technique excluding
a polyether based polyurethane elastic yarn. Consequently, it is possible to prevent
the thermal bonding yarn 23 from being dissociated from the chain stitch yarn 21,
thereby breaking the thermal bonding yarn 23 suitably.
[0064] Fig. 7 is a flowchart showing another manufacturing process for the knitted lace
fabric 120. First of all, when a preparation for a knitted fabric formation is completed
at Step b0 in the same manner as in the Step a1, the processing proceeds to Step b1
in which the manufacture of the knitted lace fabric 120 is started.
[0065] At the Step b1, a knitted fabric knitting step of forming the first precursor knitted
fabric 20 to be a precursor of the knitted lace fabric 120 is carried out in the same
manner as in the Step b1. When the knitted fabric formation is completed, the processing
proceeds to Step b2.
[0066] At the Step b2, a thermal setting step of arranging the knitted fabric into a predetermined
shape is carried out. At the thermal setting step, the knitted fabric is maintained
to have the predetermined shape. For example, the predetermined shape is flat or is
provided with pleats. At the thermal setting step, the first precursor knitted fabric
is heated to a melting temperature of the thermal bonding yarn 23 or more in a state
in which the first precursor knitted fabric is extended and is held to have a shape
to be maintained. Consequently, the thermal bonding yarn 23 is molten to stick to
another yarn. When the thermal bonding yarn 23 is caked, the knitted fabric can be
held to have a shape maintained in the thermal setting and can be prevented from being
deformed from the maintained shape. At the thermal setting step, thus, the heating
step of melting the thermal bonding yarn 23 and the breaking step of extending the
knitted fabric are carried out at the same time. When the thermal setting step is
completed, it is possible to form the knitted lace fabric 120 shown in Fig. 1 and
the processing proceeds to Step b3.
[0067] At the Step b3, a lace product including the knitted lace fabric 120 is manufactured
by using the knitted lace fabric 120 which is formed after the Step b3, and the manufacture
of the knitted lace fabric 120 is ended.
[0068] As described above, the heating step and the breaking step are carried out in parallel
at the thermal setting step of arranging the knitted fabric into a predetermined shape.
By simply carrying out the thermal setting step, consequently, it is possible to melt
the thermal bonding yarn 23 and to break the bonding yarn 23 into a plurality of portions.
By carrying out the heating step and the breaking step at the same time, thus, it
is possible to shorten a manufacturing period. While the heating step and the breaking
step are carried out at the same time in the thermal setting step of arranging the
knitted fabric into a predetermined shape in the embodiment, it is also possible to
carry out the heating step and the breaking step at the same time without intending
the thermal setting. Furthermore, the heating step and the breaking step may be carried
out in another step such as a dyeing step.
[0069] As shown in Fig. 3, in the first precursor knitted fabric 20, the chain stitch yarn
21 is subjected to chain stitching so that the first loop-shaped portion 24 and the
second loop-shaped portion 25 are formed. The first loop-shaped portion 24 and the
second loop-shaped portion 25 are alternately connected and arranged in a plurality
of stages in a wale direction W. In some cases, the first loop-shaped portion 24 is
referred to as a needle loop and the second loop-shaped portion 25 is referred to
as a sinker loop.
[0070] The first loop-shaped portion 24 and the second loop-shaped portion 25 are linked
alternately and extended in the wale direction W so that a course 26 is formed. A
plurality of courses 26 are arranged and formed in the wale direction W and are linked
to each other so that a chain stitch structure, that is, a chain stitch configuration
is formed. Furthermore, the chain stitch yarn 21 is properly swung transversely to
couple the adjacent course 26 in a course direction C so that a chain stitch structure
having a fray preventing function is formed. A portion in which the chain stitch yarn
21 is swung transversely is referred to as a run stopping portion 42.
[0071] The first loop-shaped portions 24 are formed in a substantially U shape respectively
and are arranged and disposed almost in the predetermined wale direction W and the
course direction C which is orthogonal to the wale direction W. Furthermore, each
of the first loop-shaped portions 24 is opened in an earlier stage in the wale direction
W. The first loop-shaped portions 24 are arranged in a line in the course direction
C to form a wale and are arranged in a line in the wale direction W to form the course
26.
[0072] The second loop-shaped portion 25 couples the first loop-shaped portions 24 arranged
in the wale direction W. For example, attention is paid to one second loop-shaped
portion 25a. The second loop-shaped portion 25a of interest has one end coupled to
an end of a first loop-shaped portion 24a in the same stage as the second loop-shaped
portion 25a of interest. The second loop-shaped portion 25a of interest extends from
one end thereof to the other end thereof such that the second loop-shaped portion
25a of interest is inserted through a first loop-shaped portion 24b in the earlier
stage in the wale direction W of the second loop-shaped portion 25a of interest from
one side to the other side and is thus extended toward a later stage in the wale direction
W, and is inserted through the first loop-shaped portion 24a in the same stage as
the second loop-shaped portion 25a of interest from the other side to the one side
and is thus extended toward the later stage in the wale direction W and is connected
to an end of a first loop-shaped portion 24c in the later stage in the wale direction
W of the second loop-shaped portion 25a of interest. Consequently, the loop-shaped
portions 24 and 25 are coupled to each other like a chain so that the course 26 extended
in the wale direction W is formed. The respective yarns 22 and 23, for example, the
inserting yarn 22 and the thermal bonding yarn 23 are interposed between the first
loop-shaped portion 24 and the second loop-shaped portion 25 and are thus knitted
into the course 26.
[0073] In a front face of the first precursor knitted fabric 20, the first loop-shaped portion
24 is hidden by the inserting yarn 22 and the thermal bonding yarn 23. In the front
face of the first precursor knitted fabric 20, accordingly, a pattern and a lace pattern
which are formed on the first precursor knitted fabric 20 appear more clearly as compared
with a back face.
[0074] For example, the second loop-shaped portion 25a of interest is inserted, toward the
front face side, through the first loop-shaped portion 24b in the earlier stage in
the wale direction W of the second loop-shapedportion 25a and is inserted, toward
the back face side, through the first loop-shaped portion 24a in the same stage in
the wale direction W of the second loop-shaped portion 25a, and is thus connected
to the first loop-shaped portion 24c in the later stage in the wale direction W.
[0075] The inserting yarn 22 serves to form a lace pattern in a chain stitch structure.
The inserting yarn 22 is knitted into the courses 26 which are adjacent to each other
in the course direction C respectively, thereby coupling two courses 26 which are
adjacent to each other in the course direction C. As shown in Figs. 1 and 2, the inserting
yarn 22 has a transverse swing portion extended from one of the courses 26 to the
other course 26 which are adjacent to each other in the course direction C and an
inserting yarn knitting portion knitted into the course 26.
[0076] A space surrounded by two transverse swing portions arranged in the wale direction
W and the course coupled by the transverse swing portions is provided with a through
hole inserted in a vertical direction of the knitted fabric. The transverse swing
portion of the inserting yarn 22 is selectively disposed so that the shape and arrangement
of the through hole is regulated. Consequently, a lace pattern represented by the
arrangement and shape of the through hole can be formed on the first precursor knitted
fabric 20. The through hole surrounded by the transverse swing portion and the course
26 is filled with a pattern yarn which will be described below and a pattern is thus
formed in some cases.
[0077] The inserting yarn 22 is extended to the front face side with respect to the first
loop-shaped portion 24. The inserting yarn 22 is inserted between the first loop-shaped
portion 24 and the second loop-shaped portion 25 which are preset, and is extended
in the course direction C. In the embodiment, furthermore, a plurality of inserting
yarns 22 are knitted into the chain stitch structure and are arranged and knitted
in the course direction C. A position in which each of the inserting yarns 22 is to
be knitted is properly selected by the lace pattern formed on the first precursor
knitted fabric 20.
[0078] The thermal bonding yarn 23 is implemented by a yarn having a lower melting point
temperature than the chain stitch yarn 21 and the inserting yarn 22. In the embodiment,
a yarn to be partially molten is used in a heating state at a heating step to be carried
out after the formation of the first precursor knitted fabric 20. The thermal bonding
yarn 23 is used for preventing fray of the chain stitch yarn 21 and the inserting
yarn 22 which constitute the first precursor knitted fabric 20. In the embodiment,
the thermal bonding yarn 23 is implemented by a non-covering yarn, that is, a so-called
bare yarn which is not covered with a covering yarn and is implemented by a polyurethane
elastic yarn having a melting temperature which is equal to or higher than approximately
140°C and is equal to or lower than 195°C. The thermal bonding yarn 23 is knitted
into the chain stitch structure in an extending state to a natural condition.
[0079] In the embodiment, furthermore, a yarn having a low heat resistance in the polyurethane
elastic yarns is used as the thermal bonding yarn 23. More specifically; any thermal
bonding yarn 23 in the following Table 2 is used.
[Table 2]
Type name |
Fineness (dtex) |
Breaking extension percentage (%) |
Breaking strength (cN/dtex) |
100% extension stress (cN) |
300% extension stress (cN) |
Elastic |
20 |
370 |
1.5 |
2.6 |
16.2 |
yarn |
44 |
470 |
1.1 |
3.1 |
13.5 |
[0080] In the thermal bonding yarn 23 according to the embodiment, furthermore, when a treating
time is set to be 60 minutes, an extension ratio is maintained to be 100% and a heat
and humidity treating temperature is set to be 105°C, a set ratio of approximately
85% is obtained. When the heat and humidity treating temperature is set to be 120°C,
furthermore, a set ratio of approximately 93% is obtained. When the heat and humidity
treating temperature is set to be 130°C, furthermore, a set ratio of approximately
93% is obtained.
[0081] When the extension ratio is maintained to be 100% with a treating time set to be
one minute and the heat and humidity treating temperature is set to be 120°C, furthermore,
a set ratio of approximately 78% is obtained. When the heat and humidity treating
temperature is set to be 140°C, furthermore, a set ratio of approximately 85% is obtained.
[0082] The thermal bonding yarn 23 is extended along the course and is knitted into all
of the loop-shaped portions constituting the course. Accordingly, the thermal bonding
yarn 23 is knitted into both a ground portion in which an amount of the yarn per unit
area is small and a pattern portion in which the amount of the yarn per unit area
is larger than that in the ground portion in the chain stitch structure. In the embodiment,
furthermore, the first precursor knitted fabric 20 has a plurality of thermal bonding
yarns 23 and each of the thermal bonding yarns 23 is knitted per course. Thus, the
thermal bonding yarn 23 is knitted over a whole region of the chain stitch structure.
[0083] The thermal bonding yarn 23 is disposed on the front face side (this side in a perpendicular
direction to the paper in Figs. 1 to 3) with respect to the first loop-shaped portion
24 and is disposed on the back face side with respect to the second loop-shaped portion
25. The thermal bonding yarn 23 advances zigzag in the wale direction W along the
corresponding course. For example, when the thermal bonding yarn 23 passes from one
of the courses to the other course in the wale direction W between the first loop-shaped
portion 24a and the second loop-shaped portion 25a which are of interest, it passes
from one of the courses to the other course between the first loop-shaped portion
24c and the second loop-shaped portion 25c in a wale of the later stage in the wale
direction W of the first loop-shaped portion 24a of interest (an upper part in Figs.
1 to 3).
[0084] Immediately after the knitting operation, the thermal bonding yarn 23 passes through
the front face side with respect to the first loop-shaped portion 24 and is extended
over the region at the back face side of the first precursor knitted fabric 20 with
respect to the inserting yarn 22. Accordingly, the thermal bonding yarn 23 is inserted
between the first loop-shaped portion 24 and the inserting yarn 22 in a region in
which the thermal bonding yarn 23 and the inserting yarn 22 are inserted between the
first loop-shaped portion 24 and the second loop-shaped portion 25. Furthermore, the
inserting yarn 22 is inserted between the thermal bonding yarn 23 and the second loop-shaped
portion 25. In this case, the chain stitch yarn 21 is stretched in the wale direction
W so that radii of curvature of the first loop-shaped portion 24 and the second loop-shaped
portion 25 are decreased so that the thermal bonding yarn 23 is disposed between the
inserting yarn 22 and the first loop-shaped portion 24 to come in contact with the
inserting yarn 22 and the first loop-shaped portion 24.
[0085] In the embodiment, the thermal bonding yarn 23 and the inserting yarn 22 cross each
other and pass through the first loop-shaped portion 24 and the second loop-shaped
portion 25 in the region in which the thermal bonding yarn 23 and the inserting yarn
22 are inserted between the first loop-shaped portion 24 and the second loop-shaped
portion 25. More specifically, the thermal bonding yarn 23 passes through the first
loop-shaped portion 24a of interest and the second loop-shaped portion 25a in the
wale in the same stage in the wale direction W from the side on which the first loop-shaped
portion 24a of interest is connected to the second loop-shaped portion 25b in the
earlier stage in the wale direction W (a lower part in Figs. 1 to 3).
[0086] On the other hand, the inserting yarn 22 passes through the first loop-shaped portion
24a of interest and the second loop-shaped portion 25a in the wale in the same stage
in the wale direction W from the opposite side to the side on which the first loop-shaped
portion 24a of interest is connected to the second loop-shaped portion 25b in the
earlier stage in the wale direction W. In this case, the first precursor knitted fabric
20 is stretched in the wale direction W so that the thermal bonding yarn 23 and the
inserting yarn 22 are close to each other in a portion 31 in which both of them pass
through the second loop-shaped portion 25.
[0087] In the embodiment, thus, the directions in which the thermal bonding yarn 23 and
the inserting yarn 22 are inserted between the first loop-shaped portion and the second
loop-shaped portion are different from each other in a portion of the first precursor
knitted fabric 20 in which both the thermal bonding yarn 23 and the inserting yarn
22 are knitted into the chain stitch yarn 21.
[0088] Consequently, it is possible to reduce a contact amount in which the inserting yarn
22 and the thermal bonding yarn 23 come in contact with each other, to cause the thermal
boding yarn 23 molten at the heating step to easily stick to the chain stitch yarn
21, and to easily form the fused portion 100 on the chain stitch yarn 21 in the knitted
lace fabric 120. While the inserting yarn is set in addition to the thermal bonding
yarn 23 in the embodiment, furthermore, other yarns may be set. For example, a pattern
yarn or a jacquard yarn for forming a pattern on a knitted lace and a stretch yarn
for causing the knitted lace to be elastic may be used for the yarns to cross each
other without running along the thermal bonding yarn 23.
[0089] Immediately after the knitting operation, furthermore, the inserting yarn 22 and
the thermal bonding yarn 23 which are to be knitted into the chain stitch structure
are not completely confined to the chain stitch structure. In some cases, therefore,
some of a plurality of portions in which the inserting yarn 22 and the thermal bonding
yarn 23 come in contact with each other have a portion in which the thermal bonding
yarn 23 is disposed on the front face side with respect to the inserting yarn 22.
Also in these cases, in most of the portions in which the inserting yarn 22 and the
thermal bonding yarn 23 come in contact with each other, the thermal bonding yarn
23 is disposed on the back face side with respect to the inserting yarn 22.
[0090] Furthermore, a fineness of each of the chain stitch yarn 21 and the inserting yarn
22 is equal to or smaller than 50 deniers, and particularly, a multifilament having
a fineness of 40 deniers or less is used. The chain stitch yarn 21 has such a thickness
as not to be cut when it is used as a knitted lace product and the chain stitch yarn
21 which is as thin as possible is used. For example, the chain stitch yarn 21 can
be implemented by various fibers such as nylon (a polyamide type synthetic fiber),
rayon, polyester, acryl, wool, cotton, hemp, rayon and polypropylene. Furthermore,
the various yarns used in the embodiment are only illustrative and other types of
yarns may be used. In the embodiment, the chain stitch yarn 21 is formed by a nylon
fiber and a yarn having a fineness of 30 deniers is selected. In addition, the inserting
yarn 22 is formed by a multifilament fiber and a yarn having a fineness of 30 deniers
is selected.
[0091] For the thermal bonding yarn 23, furthermore, there is used a polyurethane elastic
yarn having a fineness which is equal to or higher than 10 deniers and is equal to
or lower than300deniers. In addition, it is preferable to use a material which has
a comparatively low melting temperature and a thermoplasticity in addition to the
polyurethane elastic yarn. The thermal bonding yarn 23 may be implemented by a polyamide
type synthetic fiber. Furthermore, the thermal bonding yarn 23 may be formed by using
a non-extensible yarn.
[0092] The first precursor knitted fabric 20 according to the embodiment has a melting temperature
which is equal to or higher than the melting temperature of the thermal bonding yarn
23 after the knitting operation and is heated at a temperature which is lower than
the melting point temperatures of the residual yarns 21 and 22. Consequently, a part
of the thermal bonding yarn 23 is partially dissolved. Apart of the dissolved portions
stick to the chain stitch yarn 21 and the inserting yarn 22 which are adjacent to
each other. By carrying out caking in this state, the chain stitch yarn 21 and the
inserting yarn 22 which come in contact with the thermal bonding yarn 23 can be prevented
from being isolated from the thermal bonding yarn 23. Furthermore, the yarns 21 and
22 coming in contact with the thermal bonding yarn 23 can be bonded to each other
through the thermal bonding yarn 23. Consequently, a coupling state of the respective
yarns can be maintained so that the fray of the yarn can be prevented.
[0093] Thus, the binding of the chain stitch structure is strengthened in a sticking portion
in which the thermal bonding yarn 23 sticks to another yarn. More specifically, the
first loop-shaped portion 24 and the second loop-shaped portion 25 are bonded to each
other through the thermal bonding yarn 23. Also in the case in which a part of the
chain stitch yarn 21 is divided, consequently, it is possible to prevent the second
loop-shaped portion 25 from being isolated from the first loop-shaped portion 24.
Thus, the fray of the chain stitch yarn 21 is prevented in the bonding portion of
the first loop-shaped portion 24 and the second loop-shaped portion 25 so that the
chain stitch yarn 21 can be prevented from being frayed beyond the bonding portion.
Also in the second precursor knitted fabric 20A obtained before the thermal bonding
yarn 23 is broken, accordingly, there is an advantage that the fray can be prevented.
Description will be given to the fray preventing effect of the second precursor knitted
fabric 20A.
[0094] Fig. 8 is a knitting view for explaining a prevention of the fray of the second precursor
knitted fabric 20A according to the embodiment and Fig. 9 is a knitting view showing
the knitted lace fabric 10A according to a comparative example. In Fig. 8, the second
precursor knitted fabric 20A, which is obtained by heating the first precursor knitted
fabric 20 in which thermal bonding yarn 23 is knitted, is shown. Furthermore, in Fig.
9, the knitted lace fabric in which the thermal bonding yarn 23 is not knitted, is
shown.
[0095] As shown in Fig. 9, in the knitted lace fabric 10A according to the comparative example,
in the case in which two second loop-shaped portions 25 arranged in the wale direction
W are cut off in dividing portions 40 and 41, the dividing portion 40 in the later
stage W in the wale direction is pulled in a direction of the front face side, so
that a portion with which the chain stitch yarn 21 is to be engaged is broken and
the chain stitch structure gets loose along an earlier stage in the wale direction
W from the dividing portion 40. In the knitted lace fabric 10A according to the comparative
example, the loosening of the chain stitch structure progresses along the earlier
stage in the wale direction W to reach the run stopping portion 42, and the loosening
is suppressed in the run stopping portion 42. In order to shorten the progress of
the loosening, accordingly, it is necessary to increase the number of the run stopping
portions 42. When the number of the run stopping portions 42 is increased, the number
of yarns extended in the course direction C is increased, so that a sense of transparency
of the knitted lace fabric 10A is damaged.
[0096] On the other hand, as shown in Fig. 8, the thermal bonding yarn 23 is extended in
the wale direction W in the second precursor knitted fabric 20A according to the embodiment.
Therefore, the first loop-shaped portion 24 and the second loop-shaped portion 25
in a same stage in every wale are bonded to each other.
[0097] In the second precursor knitted fabric 20A according to the embodiment, in the case
in which two second loop-shaped portions 25 arranged in the wale direction W are cut
off in the dividing portions 40 and 41, even if the dividing portion 40 in the later
stage in the wale direction W is pulled in the direction of the front face side, the
loosening of the chain stitch structure can be hindered in a bonding portion 44 in
which the first loop-shaped port ion 24 and the second loop-shaped portion 25 are
bonded to each other in the further later stage than the dividing portion 40 in the
wale direction W because of the presence of the bonding portion 44 and a further progress
of the loosening can be prevented. As compared with the knitted lace fabric 10A according
to the comparative example, accordingly, it is possible to prevent the chain stitch
structure from being loosened. Furthermore, the loosening is suppressed in the bonding
portions 43 and 44. Therefore, it is possible to decrease or eliminate the run stopping
portions 42. As compared with the comparative example, thus, the sense of transparency
of the knitted lace can be enhanced more greatly. In the embodiment, furthermore,
the first loop-shaped portion 24 and the second loop-shaped portion 25 in the same
stage in the wale direction W are bonded to each other in every wale direction W,
so that it is possible to prevent the course from being divided in the wale direction
W, even if a part of the second loop-shaped portion 25 is divided. As described above,
in the embodiment, the thermal bonding yarn 23 is extended along the course and is
formed. As to the chain stitch structure, therefore, it is possible to increase the
binding in the wale direction W and enhancing a durability thereby.
[0098] Fig. 10 is a knitting view for explaining fray of the second precursor knitted fabric
20A according to the embodiment and Fig. 11 is a knitting view showing the knitted
lace fabric 10A according to the comparative example. In Fig. 10, the second precursor
knitted fabric 20A, which is obtained by heating the first precursor knitted fabric
20 in which thermal bonding yarn 23 is knitted, is shown. Furthermore, a knitted lace
fabric 10A according to the comparative example shown in Fig. 11 is a knitted lace
fabric 10A in which the thermal bonding yarn 23 is not knitted. In Figs. 10 and 11,
the inserting yarn 22 is knitted over a plurality of courses.
[0099] As shown in Fig. 11, in the knitted lace fabric 10A according to the comparative
example, in the case in which the inserting yarn 22 is cut off in the dividing portion
45, even if the portion 46 in one of the course directions C which is beyond at least
one course from the dividing portion 45 is pulled in the course direction C in inserting
yarn 22, so that the dividing portion 45 slips from the course and the inserting yarn
22 slips from the knitted lace fabric 10A. For example, the inserting yarn 22 is only
prevented from moving by frictional force with the chain stitch yarn 21. By great
force, therefore, the inserting yarn 22 is shifted from a knitted portion or slips
in some cases.
[0100] On the other hand, as shown in Fig. 10, the thermal bonding yarn 23 is knitted into
each course 26 in the second precursor knitted fabric 20A according to the embodiment.
Therefore, the inserting yarn 22 is bonded to the first loop-shaped portion 24 and
the second loop-shaped portion 25 for each course.
[0101] In the second precursor knitted fabric 20A according to the embodiment, in the case
in which the inserting yarn 22 is cut off in the dividing portion 45, even if the
portion 46 in one of the course directions C which is beyond at least one course from
the dividing portion 45 is pulled in the course direction C in the inserting yarn
22, bonding portions 47 and 48, in which the inserting yarn 22 and the course 26 are
bonded, are bonded to each other, so that the dividing portion 45 can be prevented
from slipping from the course 26 and a progression of the shift of the inserting yarn
22 can be prevented. In the embodiment, thus, the inserting yarn 22 is fixed to the
chain stitch structure by the bonding force of the thermal bonding yarn 23, with the
result that it is possible to prevent the inserting yarn 22 from being shifted and
slipping.
[0102] Furthermore, the courses 26 which are adjacent to each other in the course direction
C are bonded to each other through the inserting yarn 22, so that an interval between
the adjacent courses can be prevented from being expanded or narrowed. Thus, it is
possible to prevent a lace pattern of the knitted lace fabric 120 from being disarranged.
[0103] As described above, according to the embodiment, it is possible to prevent the fray
of each of yarns constituting the second precursor knitted fabric 20A. Furthermore,
even if the knitted lace fabric 120 is formed by breaking the thermal bonding yarn
23 in the second precursor knitted fabric 20A into a plurality thereof, a fray-prevention
effect in the knitted lace fabric 120 achieved in the second precursor knitted fabric
20A can be further enhanced. Consequently, it is possible to prevent the fray of the
yarn caused by a manufacturing state such as sewing or cutting operation and using
state such as wearing or washing in the knitted lace fabric 120. Thus, it is possible
to enhance quality.
[0104] According to the embodiment, furthermore, the thermal bonding yarn 23 is a bare yarn
in which a surface portion has a fusibility. When the first precursor knitted fabric
20 is heated, accordingly, a portion of the thermal bonding yarn 23 which comes in
contact with the chain stitch yarn 21 is molten and sticks to the chain stitch yarn
21. Furthermore, a portion of the thermal bonding yarn 23 which comes in contact with
the inserting yarn 22 is molten and sticks to the inserting yarn 22. According to
the embodiment, thus, an exposed portion of the thermal bonding yarn 23 which directly
comes in contact with other yarns becomes a portion to stick to the other yarns. Therefore,
an amount of the thermal bonding yarn 23 to stick to the other yarns can be increased,
so that a bonding force can be enhanced. Therefore, the fray of each yarn can be prevented
further reliably.
[0105] Furthermore, by implementing the thermal bonding yarn 23 with the non-covering yarn,
that is, the bare yarn which is not covered with the covering yarn, furthermore, it
becomes possible to further decrease the amount of the yarns in the ground portion
and to increase the difference in the density of the yarns between the ground portion
and the pattern portion. Thus, the sense of transparency of the knitted lace fabric
120 can be enhanced and the pattern can be clear.
[0106] According to the embodiment, furthermore, the thermal bonding yarn 23 is knitted
over the whole region of the chain stitch structure. Therefore, it is possible to
prevent the fray of the yarns in the whole knitted 1 knitted lace fabric 120. For
example, even if the knitted lace fabric 120 is sewn or cut in an arbitrary position,
it is possible to prevent the yarns from being frayed in a sewn portion and a cut
portion.
[0107] Furthermore, it is possible to prevent the fray of the yarns over the whole knitted
lace fabric 120. For example, in the case in which the knitted lace fabric 120 according
to the embodiment is used as the knitted lace fabric for forming the eyelash lace,
it is possible to prevent the fray of the eyelash-shaped portion. Referring to a motif
cut in which the knitted lace fabric 120 is cut in an arbitrary position, furthermore,
it is possible to prevent the fray of the cut portion. Thus, an application to a wide
lace can also be carried out. Furthermore, it is possible to prevent the fray over
the whole knitted lace fabric 120. Therefore, it is possible to use the knitted lace
fabric 120 also in a part of a coat requiring durability. As described above, according
to the embodiment, it is possible to prevent the fray of the yarn over the whole knitted
lace fabric 120. Consequently, use application can be expanded.
[0108] According to the embodiment, furthermore, the thermal bonding yarn 23 and the inserting
yarn 22 are inserted between the first loop-shaped portion 24 and the second loop-shaped
portion 25 and are thus knitted into the chain stitch structure. In the knitted lace
fabric 120, a face on the side where the first loop-shaped portion 24 is disposed
with respect to the inserting yarn 22 knitted into the chain stitch structure is a
rear face, and a face on an opposite side thereof is a front face. In the embodiment,
the inserting yarn 22 is disposed in the front face direction Z1 rather than thermal
bonding yarn 23 in a portion in which the thermal bonding yarn 23 and the inserting
yarn 22 are knitted in common. As seen from the front face of the knitted lace fabric
120, accordingly, the thermal bonding yarn 23 and the first loop-shaped portion 24
are hidden by the inserting yarn 22.
[0109] As described above, the thermal bonding yarn 23 can be hidden by the inserting yarn
22 and can be difficult to be seen from the front face. Consequently, a pattern to
be formed on the knitted lace fabric 120 can be clear. Further, even if the thermal
bonding yarn 23 is molten, it is possible to lessen an influence on the pattern seen
from the front face. Furthermore, the thermal bonding yarn 23 passes through a portion
between the first loop-shaped portion 24 and the inserting yarn 22, so that the first
loop-shaped portion 24 and the inserting yarn 22 can be bonded to each other and the
inserting yarn 22 can be prevented from being removed from the chain stitch structure.
[0110] In the embodiment, furthermore, the thermal bonding yarn 23 and the inserting yarn
22 pass through the loop-shaped portion 25 in different directions from each other
in a region in which the thermal bonding yarn 23 and the inserting yarn 22 are inserted
between the first loop-shaped portion 24 and the second loop-shaped portion 25. In
this case, the knitted lace fabric 120 is pulled in the course direction C, so that
the regions surrounded by the thermal bonding yarn 23 and the inserting yarn 22 are
close to each other in the course direction C, and then an approaching portion 34,
in which the thermal bonding yarn 23, the inserting yarn 22, the first loop-shaped
portion 24 and the second loop-shaped portion 25 approach each other, is generated.
When the first precursor knitted fabric 20 is heated in a pulling state in the course
direction C, thus, a part of the thermal bonding yarn 23 can be molten in the approaching
portion 34, so that a bonding force for bonding the thermal bonding yarn 23, the inserting
yarn 22, the first loop-shaped portion 24 and the second loop-shaped portion 25 can
be increased.
[0111] In the embodiment, furthermore, the fineness of the thermal bonding yarn 23 is set
to 10 deniers to 300 deniers and the fineness of the chain stitch yarn is set to 20
deniers to 70 deniers. When the thermal bonding yarn 23 has fineness which is smaller
than 10 deniers, there is a possibility that all of the thermal bonding yarns in the
knitted lace might be molten. Also in the case in which a part of the thermal bonding
yarn 23 is set to be molten, furthermore, there is a possibility that the amount of
bonding of the thermal bonding yarn 23 to the other yarns might be insufficient. In
this case, the fray of the yarn might be caused. When the thermal bonding yarn 23
has a fineness which is greater than 300 deniers, furthermore, the sense of transparency
of the knitted lace is deteriorated, and a sense of beauty is decreased due to decrease
of the difference in the density of the yarns between the groundportion and the pattern
portion through the thermal bonding yarn 23. Furthermore, the knitted lace is hardened.
On the other hand, in the invention, it is possible to eliminate the fray of the yarns
and to suppress reduction in the sense of beauty by setting the thermal bonding yarn
23 to have a fineness which is 10 deniers to 300 deniers. By setting the thermal bonding
yarn 23 to have a fineness of equal to or smaller than 70 deniers, furthermore, it
is possible to further suppress the reduction in the sense of beauty.
[0112] Fig. 12 is a side view showing a knitting portion of a raschel knitting machine 60
for knitting the first precursor knitted fabric 20 according to the first embodiment.
The first precursor knitted fabric 20 can be knitted by the back jacquard raschel
knitting machine, for example. The back jacquard raschel knitting machine 60 (hereinafter
referred to as a knitting machine 60) has yarn guiding means for guiding the chain
stitch yarn 21, the inserting yarn 22 and the thermal bonding yarn 23 toward a knitting
position 73 in the vicinity of a knitting needle 72. In the embodiment, the yarn guiding
means for guiding the thermal bonding yarn 23 toward the knitting position 73 is disposed
behind the yarn guiding means for guiding the inserting yarn 22 toward the knitting
position 73 in a rear part of the knitting machine. The rear part of the knitting
machine is set in a direction from a back face of the knitting needle 72 toward a
hook portion.
[0113] More specifically, the yarn guiding means provided in the knitting machine is implemented
by a guide bar for thermal bonding yarn 61, jacquard bars 62 and 63, a plurality of
pattern guide bars 64 and a base guide bar 65. The chain stitch yarn 21 is inserted
through the base guide bar 65, the inserting yarn 22 is inserted through the jacquard
bars 62 and 63, and the thermal bonding yarn 23 is inserted through the guide bar
for thermal bonding yarn 61. In the case in which a pattern yarn to be a yarn for
forming a pattern is knitted into the course 26, furthermore, the pattern yarns are
inserted through the pattern guide bars 64. Description will be given to the case
in which the pattern yarn is knitted in addition to the thermal bonding yarn 23 and
the inserting yarn 22.
[0114] Such yarn guiding means 61 to 65 are arranged radially toward the knitting position
73 in which the knitting needle 72 catches the chain stitch yarn 21 and are disposed
in order of the base guide bar 65, the pattern guide bars 64, the jacquard bars 62
and 63, and the guide bar for thermal bonding yarn 61 toward the rear part of the
knitting machine to be the direction
in which the knitting needle 72 catches the chain stitch yarn 21. Accordingly, the
yarns are arranged in the rear part of the knitting machine from a predetermined knitting
position in order of the chain stitch yarn 21, the pattern yarns, the inserting yarn
22 and the thermal bonding yarn 23.
[0115] The knitting needles 72 are arranged and formed in a direction perpendicular to an
anteroposterior direction of the knitting machine and are fixed to a needle bar 69
to be holding means for holding each of the knitting needles 72. The needle bar 69
causes each knitting needle 72 to carry out an up-down motion. Furthermore, the needle
bar 69 is operated, so that the yarns guided to the yarn guiding means 61 to 65 are
guided to predetermined knitting positions.
[0116] The respective yarn guiding means 61 to 65 carry out an overlapping (a stitch knitting
motion) for moving each yarn corresponding in a space formed in the rear part of the
knitting machine to the knitting needle 72 in a direction in which the needles 72
are arranged synchronously with the up-down motion of the knitting needle 72 and an
underlapping (inserting motion) for moving each yarn corresponding in a space formed
in the front part of the knitting machine to the knitting needle 72 in the direction
in which the knitting needles 72 are arranged. Furthermore, a so-called swing (a swing
motion) for a movement in a direction in an orthogonal direction to the direction
in which the knitting needles 72 are arranged is carried out in addition to these
lap motions. More specifically, there are two swing operations.
[0117] In a swing-in (back swing) operation to be a first swing operation, each corresponding
yarn is moved from the space formed in the front part of the knitting machine to the
space formed in the rear part of the knitting machine with respect to the knitting
needle 72 through a side of the knitting needle 72. In a swing-out (front swing) operation
to be a second swing operation, furthermore, each corresponding yarn is moved from
the space formed in the front part of the knitting machine to the space formed in
the rear part of the knitting machine with respect to the knitting needle 72 through
the side of the knitting needle 72. Guides attached to the yarn guiding means 61 to
65 are operated, so that each corresponding yarn passes in accordance with a predetermined
path around the knitting needle 72 and a knitted fabric including each corresponding
yarn is thus formed.
[0118] Furthermore, the knitting portion includes a stitch comb bar 71, a trick plate bar
68 and a tongue bar 70. In the tongue bar 70, a plurality of tongues are formed in
a tip portion corresponding to the knitting needles. The knitting machine 60 knits
the first precursor fabric 20 by the operations of the yarn guiding means 61 to 65
and the needle bar 69. The knitted lace fabric 20 formed by a knitting subsidiary
function of the stitch comb bar 71 is subsidiarily knitted and the trick plate bar
68 is caused to pass therethrough, thereby winding the first precursor knitted fabric
20 by means of a winding portion provided in the vicinity of the knitting portion.
[0119] Figs. 13A to 13E are cross sectional views schematically illustrated for explaining
movements of the knitting needle 72 and the base guide bar 65 in the chain stitch
portion, and a knitting work of the chain stitch portion of the chain stitch yarn
21 progresses in order of Figs. 13A to 13E. In the knitting needle 72, a hook portion
50 for engaging the chain stitch yarn 21 is formed in a tip portion and a knitting
needle stem 51 formed on a base end. Furthermore, in a tip portion of the tongue bar
70, a tongue 52 for opening/closing an opening formed by the hook portion 50 is formed.
The knitting needle 72 and the tongue 52 are formed to be individually ascendable/descendable
with respect to the base guide bar 65. Referring to Figs. 13A to 13E, only the knitting
operation for the course 26 will be first described and the inserting yarn 22 and
the thermal bonding yarn 23 which are to be knitted into the course 26 will be described
later.
[0120] As shown in Fig. 13A, the hook portion 50 catches a new first loop-shaped portion
24j formed by the chain stitch 21 in a state in which the base guide bar 65 is disposed
before the knitting needle 72 and the tongue 52 closes the opening of the hook portion
50. As shown in Fig. 13B, next, the knitting needle 72 is moved upward toward the
base guide bar 65 with respect to the tongue 52. Consequently, the opening of the
hook portion 50 is opened, so that the first loop-shaped portion 24j of the chain
stitch 21 caught by the hook portion 50 slips out of the hook portion 50 and is moved
to the knitting needle stem 51.
[0121] Next, the base guide bar 65 carries out the back swing with respect to the knitting
needle 72 as shown in Fig. 13C. Then, the base guide bar 65 carries out the overlapping,
and furthermore, carries out the front swing. Consequently, the chain stitch yarn
21 guided to the base guide bar 65 is moved so as to wind the knitting needle 72,
thereby forming a new first loop-shaped portion 24k. The new first loop-shaped portion
24k is caught by the hook portion 50. As shown in Fig. 13D, thereafter, the tongue
52 is moved upward toward the hook portion 50 to close the opening of the hook portion
50. At this time, the old first loop-shaped portion 24j formed on the knitting needle
stem 51 and the new first loop-shaped portion 24k with which the hook portion 50 is
engaged are formed on the knitting needle 72.
[0122] As shown in Fig. 13E, subsequently, the knitting needle 72 and the tongue 52 are
moved downward together so that the old first loop-shaped portion 24j is removed from
the knitting needle 72 and is moved to the trip plate 53 side. Then, the hook portion
50 catches the new first loop-shaped portion 24k formed by the chain stitch 21 in
a state in which the base guide bar 65 is disposed before the knitting needle 72,
so that almost the same state as that in Fig. 13A is brought. By repeating the operation
cycle shown in Figs. 13A to 13E, the first loop-shaped portion 24 is sequentially
formed, and furthermore, there is formed the course 26 in which a second loop-shaped
portion 25j coupling the first loop-shaped portions 24j and 24k is sequentially formed.
In the example, the base guide bar 65 properly carries out the underlapping, so that
the courses 26 are coupled in the wale direction W. The inserting yarns such as the
inserting yarn 22 and the thermal bonding yarn 23 are knitted into the course 26 while
the knitting work for the course 26 is carried out. Consequently, it is possible to
form the first precursor knitted fabric 20 according to the embodiment.
[0123] Figs. 14A to 14C are cross sectional views schematically illustrating for explaining
movements of the jacquard bar 62 and the guide bar for thermal bonding yarn 61, and
the operation progresses in order of Figs. 14A to 14C. Figs. 14A, 14B and 14C correspond
to Figs. 13C, 13D and 13E respectively, and additionally show the jacquard bar 62
and the guide bar for thermal bonding yarn 61 respectively. As described above, in
the knitting machine 60, the jacquard bars 62 and 63 are disposed behind the base
guide bar 65 for guiding the chain stitch yarn in the rear part of the knitting machine.
Furthermore, the guide bar for thermal bonding yarn 61 to be a guide bar for thermal
bonding yarn is disposed behind the jacquard bars 62 and 63 in the rear part of the
knitting machine.
[0124] As shown in Figs. 14A and 14C, in a state in which the base guide bar 65 is disposed
in the rear part of the knitting machine with respect to the knitting needle 72, the
jacquard bar 62 and the guide bar for thermal bonding yarn 61 are also disposed in
the rear part of the knitting machine with respect to the knitting needle 72. As shown
in Fig. 14B, furthermore, the jacquard bar 62 and the guide bar for thermal bonding
yarn 61 are also disposed before the knitting needle 72 in a state in which the base
guide bar 65 is disposed in the front part of the knitting machine with respect to
the knitting needle 72.
[0125] Furthermore, the jacquard bar 62 and the guide bar for thermal bonding yarn 61 carry
out the underlapping in a state in which the base guide bar 65 performs a back swing
so that the thermal bonding yarn 23 and the inserting yarn 22 which are guided cross
the chain stitch yarn 21 as shown in Fig. 14B. When a loop is newly formed with the
chain stitch yarn 21 in this state, the thermal bonding yarn 23 and the inserting
yarn 22 are knitted into the loop. Thus, the guide bar for thermal bonding yarn 61
and the jacquard bar 62 are operated synchronously with the swing operation of the
base guide bar 65.
[0126] The jacquard bar 62 is disposed ahead of the guide bar for thermal bonding yarn 61
in the front part of the knitting machine. In the case in which the thermal bonding
yarn 23 and the inserting yarn 22 are knitted into the chain stitch portion formed
by the base guide bar 65, consequently, the thermal bonding yarn 23 guided to the
knitting position is disposed behind the inserting yarn 22 guided to the knitting
position in the rear part of the knitting machine and the inserting yarn 22 is positioned
on the front face side of the first precursor knitted fabric 20 from the thermal bonding
yarn 23.
[0127] Figs. 15A and 15B are structural views schematically illustrating an S region in
Fig. 3, and Fig. 15A is a structural view of the chain stitch yarn 21 and Fig. 15B
is a structural view of the thermal bonding yarn 23.
[0128] For example, a knitting needle 72 placed in an arbitrary position is set to be a
first knitting needle 72a, an adjacent knitting needle 72 to the first knitting needle
72a in one course direction C is set to be a second knitting needle 72b, and an adjacent
knitting needle 72 to the second knitting needle 72b in another course direction C
is set to be a third knitting needle 72c. An interval between the first knitting needle
72a and the knitting needle 72 disposed in another course direction C with respect
to the first knitting needle 72a is set to be a first knitting needle interval L1,
an interval between the first knitting needle 72a and the second knitting needle 72b
is set to be a second knitting needle interval L2, an interval between the second
knitting needle 72b and the third knitting needle 72c is set to be a third knitting
needle interval L3, and an interval between the third knitting needle 72c and the
knitting needle 72 disposed in one course direction C with respect to the third knitting
needle 72c is set to be a fourth knitting needle internal L4.
[0129] The base guide bar 65 for guiding each chain stitch yarn 21 carries out the same
knitting operation as that of the chain stitch yarn 21. In a first course C1, description
will be given by paying attention to a chain stitch yarn guide for catching the chain
stitch yarn 21 on the second knitting needle 72b and description for the residual
chain stitch yarn guides will be omitted.
[0130] As shown in Fig. 15A, in the first course C1, a chain stitch yarn guide of interest
carries out a back swing in the third knitting needle interval L3, and then carries
out the overlapping to pass through the second knitting needle interval L2 and performs
a front swing. In a second course C2, the chain stitch yarn guide of interest carries
out the back swing in the second knitting needle interval L2, and then carries out
the overlapping to pass through the second knitting needle interval L2 and performs
the front swing.
[0131] In a third course C3, the chain stitch yarn guide of interest carries out the underlapping
in the fourth knitting needle interval L4, carries out the back swing in the fourth
knitting needle interval L4, and then carries out the overlapping to pass through
the third knitting needle interval L3 and performs the front swing. In a fourth course
C4, the chain stitch yarn guide of interest carries out the back swing in the third
knitting needle interval L3, and then carries out the overlapping to pass through
the fourth knitting needle interval L4 and performs the front swing. In a fifth course
C5, the chain stitch yarn guide of interest carries out the back swing in the fourth
knitting needle interval L4, and then carries out the overlapping to pass through
the third knitting needle interval L3 and performs the front swing.
[0132] The same operation as that in the fourth course C4 is carried out in a sixth course
C6 and the same operation as that in the fifth course C5 is carried out in a seventh
course C7. In an eighth course C8, the chain stitch yarn guide of interest carries
out the underlapping in the fourth knitting needle interval L4, carries out the back
swing in the fourth knitting needle interval L4, and then carries out the overlapping
to pass through the third knitting needle interval L3 and performs the front swing.
In a ninth course C9, the chain stitch yarn guide of interest carries out the underlapping
in the second knitting needle interval L2, carries out the back swing in the second
knitting needle interval L2, and then carries out the overlapping to pass through
the third knitting needle interval L3 and performs the front swing.
[0133] Thus, the base guide bar 65 repetitively carries out an operation for catching the
predetermined chain stitch yarn 21 on each knitting needle 72 in each course by using
a guide provided for each chain stitch yarn 21. Consequently, it is possible to form
the chain stitch portion extended like a chain. In the embodiment, furthermore, the
knitting machine 60 properly carries out the underlapping in a process for catching
the chain stitch yarn 21 on the knitting needle 72 in each source. Consequently, the
second loop-shaped portion 25 can be caused to swing transversely in the wale direction
W and another wale direction W so that the adjacent wales 26 in the wale direction
W can be coupled to form a chain stitch structure having a fray preventing function.
[0134] The thermal bonding yarn 23 carries out a swing operation synchronously with the
base guide bar 65 by the guide bar for thermal bonding yarn 61. The guide bar for
thermal bonding yarn 61 which serves to guide each of the thermal bonding yarns 23
carries out the same knitting operation for the each of the thermal bonding yarns
23. In the first course C1, description will be given by paying attention to the thermal
bonding yarn guide for positioning the thermal bonding yarn 23 in the second knitting
needle interval L3, and the description for the residual thermal bonding yarn guides
will be omitted.
[0135] As shown in Fig. 15B, in the first course C1, the thermal bonding yarn guide of interest
carries out the underlapping in the second knitting needle interval L2 to reach the
third knitting needle interval L3. In the second course C2, furthermore, the thermal
bonding yarn guide carries out the underlapping in the third knitting needle interval
L3 to reach the second knitting needle interval L2. The thermal bonding yarn guide
of interest sequentially repeats the operations of the first course C1 and the second
course after the second course C2. Thus, the thermal bonding yarn 23 is reciprocated
with the underlapping between the two adjacent knitting needle intervals synchronously
with the swing operation of the base guide bar 65 by the guide bar for thermal bonding
yarn 61.
[0136] Referring to the inserting yarn other than the thermal bonding yarn, for example,
the inserting yarn 22, similarly, the jacquard bar 62 repeats the underlapping for
a predetermined distance and direction in a predetermined position synchronously with
the swing operation of the base guide bar 65. For a pattern yarn, similarly, the base
guide bar 64 repeats the underlapping for a predetermined distance and direction in
a predetermined position synchronously with the swing operation of the base guide
bar 65.
[0137] Thus, the guide bar for thermal bonding yarn 61, the jacquard bars 62 and 63, a plurality
of pattern guide bars 64, the base guide bar 65 and the knitting needle 72 carry out
the knitting operation so that a knitted lace fabric portion can be formed in the
S region. In the knitting machine 60, the base guide bar 65, the jacquard bars 62
and 63 and the guide bar for thermal bonding yarn 61 are disposed in order toward
the rear part of the knitting machine so that the inserting yarn 22 can be disposed
on the front face side of the first precursor knitted fabric 20 with respect to the
thermal bonding yarn 23. Thus, it is possible to form the first precursor knitted
fabric 20 according to the embodiment shown in Fig. 2.
[0138] Fig. 16 is a flowchart showing a procedure for manufacturing a knitted lace product.
First of all, when a pattern of a knitted lace to be formed is determined at Step
s0, the processing proceeds to Step s1. At the Step s1, the chain stitch yarn 21,
the inserting yarn 22, the thermal bonding yarn 23 and the pattern yarn are prepared
and an operation program for each yarn guiding means of the knitting machine 60 is
input in order to obtain the pattern determined at the Step s0. Next, the knitting
machine 60 is operated. Consequently, the first precursor knitted fabric 20 having
a desirable pattern can be formed. When the work for forming the first precursor knitted
fabric 20 is completed, the processing proceeds to Step s2.
[0139] At the Step s2, the first precursor knitted fabric 20 formed at the Step s1 is dyed.
When the dyeing operation is completed, the processing proceeds to Step s3. At Step
s3, the first precursor knitted fabric 20 is heated to a predetermined temperature
so as to be arranged. At this time, the first precursor knitted fabric 20 is heated
in a pulling state in the course direction C. Consequently, the knitted fabric is
arranged, and furthermore, a part of the thermal bonding yarn 23 is molten and sticks
to another adjacent yarn. The first precursor knitted fabric 20 is heated for a predetermined
duration at a predetermined temperature, and the processing proceeds to Step s4. In
the embodiment, a state at 180 to 195°C is maintained for 60 seconds to manufacture
the knitted lace fabric 120. Since the knitted lace fabric 120 is obtained by heating
the first precursor knitted fabric 20, a part of the thermal bonding yarn 23 is fixed
to another yarn. Furthermore, the knitted lace fabric 120 is extended compared to
after Step s2, so that the thermal bonding yarn 23 is broken into a plurality thereof.
[0140] At Step s4, the knitted lace fabric 120 is cut and the cut knitted lace fabric 120
is sewn, thereby manufacturing a knitted lace product. When the knitted lace product
is manufactured, the processing proceeds to Step s5 in which the work is ended.
[0141] At the cutting and sewing step in the Step s4, a part of the thermal bonding yarn
23 is fixed to another yarn. Therefore, the binding of the chain stitch structure
is strengthened. In the cutting or sewing operation, accordingly, each yarn can be
prevented from being frayed so that the yield of the knitted lace product which is
manufactured can be enhanced, and quality can be improved. Referring to the knitted
lace product which is manufactured, similarly, the binding of the chain stitch structure
is strengthened. Therefore, it is possible to prevent the fray from being caused by
use for wearing or washing, thereby enhancing a durability of the knitted lace product.
[0142] At the heating step shown in the Step s3, furthermore, the first precursor knitted
fabric 20 is heated in the pulling state in the course direction C so that the inserting
yarn 22 and the thermal bonding yarn 23 approach the loop-shaped portions 24 and 25.
Consequently, the loop-shaped portions 24 and 25 and the inserting yarn 22 can be
bonded strongly by the thermal bonding yarn 23.
[0143] Fig. 17 is a view showing a knitting structure, typically illustrating a part of
a first precursor knitted fabric 20B according to a second embodiment of the invention.
In the first precursor knitted fabric 20B according to the second embodiment, a direction
in which a thermal bonding yarn 23 passes through a second loop-shaped portion 25
is different from that in the first precursor knitted fabric 20 according to the first
embodiment, and the other structures are the same. Accordingly, the same structures
as those in the first precursor knitted fabric 20 according to the first embodiment
have the same reference numerals and description will be omitted.
[0144] In the embodiment, the thermal bonding yarn 23 passes through the second loop-shaped
portion 25 in the same direction as a inserting yarn 22 and is inserted between a
first loop-shaped portion 24 and the inserting yarn 22. More specifically, the thermal
bonding yarn 23 and the inserting yarn 22 pass through a first loop-shaped portion
24a of interest and a second loop-shaped portion 25a in the same stage in a wale direction
from an opposite side to a side on which the first loop-shaped portion 24a of interest
is connected to the second loop-shaped portion 25b in an earlier stage C1 in the wale
direction.
[0145] Thus, the thermal bonding yarn 23 is inserted through the second loop-shaped portion
25 in the same direction as the inserting yarn 22 so that the number of contact portions
of the inserting yarn 22, and the thermal bonding yarn 23 can be increased and a bonding
force for the thermal bonding yarn 23 to bond the inserting yarn 22 can be enhanced.
Consequently, it is possible to prevent the fray of the inserting yarn 22 more reliably.
[0146] As another embodiment, furthermore, the invention also includes the case in which
the thermal bonding yarn 23 and the inserting yarn 22 pass through the first loop-shaped
portion 24a of interest and the second loop-shaped portion 25a in the same stage in
the wale direction W from the side on which the first loop-shaped portion 24a of interest
is connected to the second loop-shaped portion 25b in the earlier stage in the wale
direction W.
[0147] Furthermore, the invention also includes the case in which the thermal bonding yarn
23 passes through the second loop-shaped portion 25a in the same stage in the wale
direction W as the first loop-shaped portion 24a of interest from the side on which
the first loop-shaped portion 24a of interest is connected to the second loop-shaped
portion 25b in the earlier stage in the wale direction W, and the inserting yarn 22
passes through the second loop-shaped portion 25a in the same stage in the wale direction
W as the first loop-shaped portion 24a of interest from the opposite side to the side
on which the first loop-shaped portion 24a of interest is connected to the second
loop-shaped portion 25b in the earlier stage in the wale direction W.
[0148] Fig. 18 is a view showing a knitting structure, schematically illustrating a part
of a first precursor knitted fabric 20D according to a third embodiment of the invention.
Fig. 19 is a view showing a knitting structure, schematically illustrating the first
precursor knitted fabric 20D in which yarns other than a chain stitch yarn 21, a thermal
bonding yarn 23 and a stretch yarn 27 are omitted. In the first precursor knitted
fabric 20D according to the third embodiment, the elastic stretch yarn 27 is further
knitted separately from the thermal bonding yarn 23 as compared with the first precursor
knitted fabric 20B according to the second embodiment and the other structures are
the same. Accordingly, the same structures as those in the first precursor knitted
fabric 20 according to the first embodiment have the same reference numerals and description
will be omitted.
[0149] The first precursor knitted fabric 20D according to the third embodiment is knitted
in a state in which the stretch yarn 27 is extended separately from the thermal bonding
yarn 23 so that the first precursor knitted fabric 20D obtained after the knitting
contracts. Consequently, it is possible to give an elasticity to the first precursor
knitted fabric 20D. For example, a polyurethane elastic yarn, a so-called spandex
is used for the stretch yarn.
[0150] The stretch yarn 27 is extended to the first loop-shaped portion 24 side with respect
to the inserting yarn 22. Furthermore, the stretch yarn 27 and the thermal bonding
yarn 23 cross each other and pass through the second loop-shaped portion 25 and are
knitted into the chain stitch structure. In other words, the thermal bonding yarn
23 is knitted while extending in a different direction from a direction in which the
stretch yarn 27 extends. The stretch yarn 27 is knitted into each of courses and thus
passes zigzag in the wale direction W along the courses respectively.
[0151] In the embodiment, the stretch yarn 27 passes through a first loop-shaped portion
24a of interest and a second loop-shaped portion 25a in the same stage in a wale direction
from a side on which the first loop-shaped portion 24a of interest is connected to
the second loop-shaped portion 25b in an earlier stage C1 in the wale direction. Furthermore,
the inserting yarn 22 and the thermal bonding yarn 23 pass through the first loop-shaped
portion 24a of interest and the second loop-shaped portion 25a in the same stage in
the wale direction from an opposite side to a side on which the first loop-shaped
portion 24a of interest is connected to the second loop-shaped portion 25b in the
earlier stage in the wale direction W. In a portion in which the stretch yarn 27,
the thermal bonding yarn 23 and the inserting yarn 22 pass through the same loop together,
accordingly, the stretch yarn 27 crosses the thermal bonding yarn 23 and the inserting
yarn 22.
[0152] Referring to the case in which the stretch yarn 27 is knitted into the first precursor
knitted fabric 20D as in the third embodiment, it is possible to obtain the same advantages
as those in the first embodiment. More specifically, the thermal bonding yarn 23 bonds
another yarn so that the fray of each yarn can be prevented. Furthermore, the thermal
bonding yarn 23 bonds the stretch yarn 27 and the chain stitch yarn 21 so that it
is possible to prevent a so-called span slip in which the stretch yarn 27 slips from
the chain stitch structure.
[0153] In the third embodiment, furthermore, the first precursor fabric 20D is pulled in
the course direction C so that regions surrounded by the stretch yarn 27 and the inserting
yarn 22 approach each other in the course direction C to generate an approaching portion
34 in which the thermal bonding yarn 23, the inserting yarn 22, the stretch yarn 27,
the first loop-shaped portion 24 and the second loop-shaped portion 25 approach each
other. By heating the first precursor knitted fabric 20D in the pulling state in the
course direction C, thus, it is possible to melt a part of the thermal bonding yarn
23 in the approaching portion 34. Thus, it is possible to increase a bonding force
for bonding the thermal bonding yarn 23, the stretch yarn 27, the inserting yarn 22,
the first loop-shaped portion 24 and the second loop-shaped portion 25.
[0154] In the embodiment, the inserting yarn 22 and the thermal bonding yarn 23 are extended
in the same direction. Consequently, the number of the contact portions in which the
thermal bonding yarn 23 comes in contact with the inserting yarn 22 can be increased
and the inserting yarn 22 can be prevented from slipping off more reliably. Furthermore,
the thermal bonding yarn 23 and the stretch yarn 27 cross each other so that the thermal
bonding yarn 23 is bonded to the stretch yarn 27. Thus, it is possible to lessen restraining
portions for restraining the stretch yarn 27. Consequently, it is possible to prevent
a span slip while suppressing a reduction in elasticity of the knitted lace fabric.
[0155] In the embodiment, furthermore, the directions in which the thermal bonding yarn
23 and the stretch yarn 27 are inserted between the first loop-shaped portion and
the second loop-shaped portion are different from each other in a portion of the first
precursor knitted fabric 20 in which both the thermal bonding yarn 23 and the stretch
yarn 27 are knitted into the chain stitch yarn 21.
[0156] Consequently, it is possible to reduce a contact amount in which the stretch yarn
27 and the thermal bonding yarn 23 come in contact with each other, to cause the thermal
boding yarn 23 molten at the heating step to easily stick to the chain stitch yarn
21, and to easily form the fused portion 100 on the chain stitch yarn 21 in the knitted
lace fabric 120.
[0157] The thermal bonding yarn 23 and the stretch yarn 27 are formed by the same kind of
polyurethane based materials, and the chain stitch yarn 21 is formed of a different
material from the thermal bonding yarn 23 such as nylon (a polyamide type synthetic
fiber) in some cases. In these cases, when the thermal bonding yarn 23 sticks to the
stretch yarn 27 formed of the same kind of material, it is hard to dissociate. On
the other hand, when the thermal bonding yarn 23 sticks to the chain stitch yarn 21
formed of a different material, it can easily be dissociated.
[0158] In the case in which the thermal bonding yarn 23 sticks to both the stretch yarn
27 and the chain stitch yarn 21, it is easily dissociated from the chain stitch yarn
21. In the embodiment, it is possible to prevent the thermal bonding yarn 23 from
sticking to both the stretch yarn 27 and the chain stitch yarn 21. Therefore, it is
possible to reduce a possibility that the thermal bonding yarn 23 might be dissociated
from the chain stitch yarn 21. Thus, the fused portion 100 can be caused to remain
in the chain stitch yarn 21.
[0159] Fig. 20 is a view showing a knitting structure, schematically illustrating a part
of a first precursor knitted fabric 20E according to a fourth embodiment of the invention.
In the first precursor knitted fabric 20E according to the fourth embodiment, a direction
in which a stretch yarn 27 is extended is different from that in the first precursor
knitted fabric 20D according to the third embodiment and the other structures are
the same. In the embodiment, the stretch yarn 27 passes through a first loop-shaped
portion 24a of interest and a second loop-shaped portion 25a in the same stage in
a wale direction W from an opposite side to a side on which the first loop-shaped
portion 24a of interest is connected to a second loop-shaped portion 25b in an earlier
stage W in the wale direction. In the case in which the stretch yarn 27, a inserting
yarn 22 and a thermal bonding yarn 23 pass through the same second loop-shaped portion
25 together, accordingly, they pass in the same direction. In a portion in which the
stretch yarn 27, the inserting yarn 22 and the thermal bonding yarn 23 pass through
the same second loop-shaped portion together, the yarns 22, 23 and 27 are placed in
close positions to each other. In the case in which the thermal bonding yarn 23 is
molten, therefore, it is possible to increase a force for bonding the inserting yarn
22 to the stretch yarn 27.
[0160] Fig. 21 is a side view showing a knitting portion of a back jacquard raschel knitting
machine 60C for knitting the first precursor knitted fabrics 20D and 20E according
to the third and fourth embodiments. In the knitting machine 60, a guide bar for stretch
yarn 66 to be yarn guiding means for guiding the stretch yarn 27 toward the knitting
position 73 is disposed between the jacquard bar 62 and the guide bar for thermal
bonding yarn 61. Since the other structures are the same as those in the knitting
machine shown in Fig. 12, description will be omitted.
[0161] Thus, the guide bar for stretch yarn 66 and the guide bar for thermal bonding yarn
61 are disposed so that the guide bar for stretch yarn 66 and the guide bar for thermal
bonding yarn 61 are provided on a back face side with respect to the inserting yarn
22. In the case in which the knitted lace fabric 120 is seen from a front face side,
consequently, the stretch yarn 27 and the thermal bonding yarn 23 are hidden by the
inserting yarn 22. Thus, the pattern of the knitted lace fabric can be clear. By causing
the operations of the jacquard bars 62 and 63, the guide bar for stretch yarn 66 and
the guide bar for thermal bonding yarn 61 to be different from each other, furthermore,
it is possible to knit the first precursor knitted fabric 20D and 20E described in
the third and fourth embodiments. Furthermore, the guide bar for stretch yarn and
the guide bar for thermal bonding yarn may be disposed to be longitudinally reverse.
In this case, a longitudinal relationship between the stretch yarn and the thermal
bonding yarn is reverse in the knitted lace fabrics according to the third and fourth
embodiments. The case in which the stretch yarn and the thermal bonding yarn are inverted
longitudinally is also included in the invention. In addition to the back jacquard
knitting machine, the knitted lace fabric formed by a front jacquard knittingmachine
in which the jacquard bars 62 and 63 are disposed before the knitting machine from
the pattern yarn is also included in the invention in the case in which the thermal
bonding yarn 23 is knitted.
[0162] Fig. 22 is a view showing a knitting structure, schematically illustrating a part
of a first precursor knitted fabric 20F according to a fifth embodiment of the invention.
Although it is preferable that a thermal bonding yarn 23 should be disposed on a back
face side with respect to the inserting yarn 22, the case in which the thermal bonding
yarn 23 is knitted into a front face side with respect to the inserting yarn 22 is
also included in the invention as shown in Fig. 22. Fig. 23 is a side view showing
a knitting portion of a back jacquard raschel knitting machine 60F for knitting the
first precursor knitted fabric 20F according to the fifth embodiment. In the knitting
machine 60, the guide bar for thermal bonding yarn 61 is disposed in a front part
of the knitting machine from the jacquard bar 62. Since the other structures are the
same as those in the knitting machine shown in Fig. 20, description will be omitted.
[0163] Also in the first precursor knitted fabrics 20B, and 20D to 20F according to the
second to fifth embodiments as described above, it is possible to obtain the same
advantages as those in the first embodiment. Further more, the embodiment according
to the invention is a simple example of the invention and the structures can be changed
within the range of the invention. For example, although the thermal bonding yarn
23 and the inserting yarn 22 are knitted into the chain stitch structure having a
fray preventing function in the embodiment, it is sufficient that the knitted fabric
to be a base is formed by a chain stitch and the chain stitch structure is not restricted.
For example, the same advantages can be obtained also in a chain stitch structure
in which the second loop-shaped portion of the chain stitch yarn 21 does not swing
transversely, that is, a chain stitch structure having no fray stopping effect. Furthermore,
the knitted fabric to be the base may be a tulle knitted fabric in addition to a basic
chain stitch structure and may be formed to have a power net structure. By the formation
into the power net structure, it is possible to form an elastic clear pattern in multiple
directions. Furthermore, the knitted fabric to be the base may be a wide lace (allover
lace) and a narrow lace.
[0164] Furthermore, the knitted lace fabric formed by the knitting machine according to
the embodiment becomes elastic by knitting a spandex into the chain stitch structure.
The invention is not restricted thereto. More specifically, a knitted lace fabric
formed by a knitting machine which does not knit the spandex is also included as the
knitting machine according to another embodiment of the invention. In this case, the
knitted lace fabric is hardly elastic but is a so-called rigid knitted lace fabric.
Furthermore, the thermal bonding yarn 23 may be a yarn whose elasticity is low or
a yarn which is not elastic. The thermal bonding yarn 23 may consist of a material
other than the aforementioned material, if the yarn can be broken after a weld.
[0165] In the embodiment, furthermore, the inserting yarn may be a pattern yarn or a floating
yarn. Furthermore, the thermal bonding yarn 23 does not need to be knitted into all
of the chain stitch portions but may be knitted into the chain stitch portion at an
interval in the course direction C and the wale direction CW. Thus, the knitted lace
fabric structures according to the embodiments are only illustrative and it is possible
to properly change a structure of a knitted fabric to be a base, a way of knitting
each inserting yarn and types of the chain stitch yarn and each of the inserting yarns.
Although the thermal bonding yarn 23 is set to be a non-covering yarn, furthermore,
it may be implemented by a covering yarn constituted by a core yarn and a covering
yarn.
[0166] In each of the embodiments, the following correspondences (1) to (7) can be applied.
(1) A knitted lace fabric having a chain stitch structure in which a plurality of
loop-shaped portions are formed with a chain stitch yarn, comprising a ground portion
including a portion in which a thermal bonding yarn having a lower melting temperature
than the chain stitch yarn is knitted in the chain stitch structure and having a nondense
yarn, and a pattern portion including a portion in which the thermal bonding yarn
and an inserting yarn for forming a pattern are knitted in the chain stitch structure
and having a dense yarn.
There are provided a pattern portion in which an amount of a yarn per unit area is
large and a ground portion in which the amount of the yarn per unit area is small.
By combining the pattern portion and the ground portion, it is possible to make a
contrast on a knitted fabric depending on a difference in a density between the yarns
and to form a knitted lace fabric having a pattern. The knitted lace fabric is heated
to a temperature which is lower than a melting temperature of a chain stitch yarn
and is equal to or higher than a melting temperature of a thermal bonding yarn so
that a part of the thermal bonding yarn is partially fused. A part of the dissolved
portion sticks to a chain stitch yarn and an inserting yarn. By carrying out caking
in this state, the chain stitch yarn and the inserting yarn which come in contact
with the thermal bonding yarn can be prevented from being isolated from the thermal
bonding yarn in a knitted lace manufactured by using the knitted lace fabric. Furthermore,
the yarns coming in contact with the thermal bonding yarn can be bonded to each other
through the thermal bonding yarn. Consequently, a coupling state of the respective
yarns can be maintained so that fray of the yarns can be prevented.
The binding of a chain stitch structure is strengthened in a sticking portion in which
the thermal bonding yarn sticks to another yarn. Also in the case in which a part
of the chain stitch yarn constituting the chain stitch structure is divided, consequently,
the chain stitch structure can be hindered from being frayed in the sticking portion
and the chain stitch structure can be prevented from being frayed beyond the sticking
portion. Furthermore, a part of the thermal bonding yarn sticks to a portion in which
the inserting yarn and the chain stitch yarn cross each other. Consequently, it is
possible to prevent the inserting yarn from being shifted or separated from the chain
stitch structure. In the case in which the thermal bonding yarn is extended over two
adjacent chain stitch yarns, furthermore, it is possible to prevent the two adjacent
chain stitch yarns from being separated from each other by bonding the inserting yarns
to the respective chain stitch yarns through the thermal bonding yarn.
Thus, it is possible to prevent the fray of each yarn for a knitted lace manufactured
by heating a knitted lace fabric. For example, it is possible to prevent the fray
of the yarn caused by a manufacturing state such as sewing or cutting of the knitted
lace and the fray of the yarn caused by a using state such as wearing or washing.
Thus, it is possible to enhance quality. Furthermore, the chain stitch structure is
achieved by yarns other than the thermal bonding yarn. By using a yarn having a heat
resistance as a chain stitch yarn, therefore, it is possible to stabilize a configuration
of the whole knitted lace.
In the case in which the chain stitch structure is formed by using the thermal bonding
yarn, for example, the thermal bonding yarn is to be thickened in order to leave the
chain stitch structure also after heating. Consequently, the number of the yarns to
constitute the ground portion is increased so that a difference in a density of the
yarn between the ground portion and the pattern portion is reduced. On the other hand,
the chain stitch structure is formed by using different chain stitch yarns from the
thermal bonding yarn so that the thermal bonding yarn does not need to be thickened
in order to leave the chain stitch structure and it is possible to thin the chain
stitch yarn and the thermal bonding yarn. By decreasing an amount per unit volume
of the yarn constituting the ground portion, consequently, it is possible to increase
the difference in the density of the yarn between the ground portion and the pattern
portion. As a result, a sense of transparency of a knitted lace can be enhanced and
a pattern can be clear. Furthermore, it is possible to reduce an amount of melting
of the thermal bonding yarn. By reducing the influence of a molten portion on the
whole knitted lace, it is possible to prevent the pattern from being damaged. Furthermore,
the chain stitch yarn can be thinned. Therefore, it is possible to cause the knitted
lace to be soft, in other words, to be easily deformable. Consequently, the knittedlace
can be suitably used for a cloth such as underwear.
(2) The knitted lace fabric wherein the thermal bonding yarn is extended in a wale
direction in which a plurality of loop-shaped portions are formed in series and is
knitted in a chain stitch structure.
The thermal bonding yarn is extended along the wale and is thus knitted in the chain
stitch structure. Therefore, it is possible to increase binding in a knitting direction
for the chain stitch structure. Consequently, it is possible to decrease a transverse
swing portion of the chain stitch yarn to be formed for preventing the fray of the
chain stitch structure, that is, a run stopping portion. Thus, it is possible to decrease
the run stopping portion to be formed on the knitted lace obtained by heating the
knitted lace fabric. Therefore, it is possible to prevent the yarn from being undesirably
extended between adj acent courses, thereby enhancing a sense of beauty more greatly.
(3) The knitted lace fabric wherein the thermal bonding yarn is a bare yarn having
a fusibility in a surface portion.
The thermal bonding yarn is a bare yarn in which a surface portion has a heat solubility.
When the knitted lace fabric is heated, accordingly, a portion of the thermal bonding
yarn which comes in contact with the chain stitch yarn is molten and sticks to the
chain stitch yarn. Furthermore, the portion of the thermal bonding yarn which comes
in contact with the inserting yarn is molten and sticks to the inserting yarn.
Thus, an exposed portion of the thermal bonding yarn which comes in contact with the
other yarn sticks to the other yarn. Consequently, it is possible to increase the
amount of sticking of the thermal bonding yarn to the other yarn, thereby enhancing
a bonding force. Accordingly, it is possible to prevent the fray of each yarn more
reliably. By implementing the thermal bonding yarn with a non-covering yarn, that
is, a bare yarn which is not covered with a covering yarn, furthermore, it is possible
to decrease the amount of the yarn in the ground portion more greatly. Thus, it is
possible to increase a difference in a density of the yarn between the ground portion
and the pattern portion, thereby enhancing a sense of transparency of the knitted
lace and causing a pattern to be clear.
(4) The knitted lace fabric wherein the thermal bonding yarn is knitted over a whole
region of the chain stitch structure.
The thermal bonding yarn is knitted over the whole region of the chain stitch structure.
Consequently, it is possible to prevent the fray of the yarn over the whole knitted
lace. For example, also in the case in which the knitted lace is sewn or cut in an
optional position, it is possible to prevent the yarn from being frayed in a sewing
portion and a cutting portion. Thus, it is possible to prevent the fray of the yarn
over the whole knitted lace. Consequently, it is possible to increase the uses. For
example, it is possible to prevent the fray over the whole knitted lace. Thus, the
knitted lace can also be used for a part of a coat requiring a durability.
(5) The knitted lace fabric wherein the chain stitch portion has a first loop-shaped
portion and a second loop-shaped portion linked alternately and arranged in a plurality
of stages in a wale direction, the second loop-shaped portion of interest is inserted
through the first loop-shaped portion in an earlier stage in a direction of the second
loop-shaped portion and is extended toward a later stage in the wale direction, and
is inserted through the first loop-shaped portion in the same stage in the wale direction
of the second loop-shaped portion and is linked to the first loop-shaped portion in
the later stage in the wale direction, and is thus formed like a chain and is extended
in the wale direction, and an inserting yarn is inserted between the first loop-shaped
portion and the second loop-shaped portion and a thermal bonding yarn is inserted
between the inserting yarn and the first loop portion in a portion in which both the
thermal bonding yarn and the inserting yarn are knitted.
The thermal bonding yarn and the inserting yarn are inserted between the first loop-shaped
portion and the second loop-shaped portion and are thus knitted into the chain stitch
structure. In the knitted lace fabric, a plane on a side where the first loop-shaped
portion is disposed is a rear face and a plane on an opposite side is a front face
with respect to the inserting yarn to be knitted into the chain stitch structure.
The inserting yarn is disposed on the front face side with respect to the thermal
bonding yarn in a portion in which the thermal bonding yarn and the inserting yarn
are knitted in common. As seen from the front face of the knitted lace fabric, accordingly,
the thermal bonding yarn and the first loop-shaped portion are hidden by the inserting
yarn.
The thermal bonding yarn can be hidden by the inserting yarn and can be seen from
the front face with difficulty. Referring to the knitted lace formed by heating the
knitted lace fabric, consequently, it is possible to cause the formed pattern to be
clear. Also in the case in which the thermal bonding yarn is molten, furthermore,
it is possible to lessen the influence on the pattern seen from the front face. Furthermore,
the thermal bonding yarn passes through a portion between the first loop-shaped portion
and the inserting yarn so that the first loop-shaped portion and the inserting yarn
can be bonded to each other and the inserting yarn can be prevented from being removed
from the chain stitch structure.
(6) The knitted lace fabric wherein the chain stitch structure has portions in which
a thermal bonding yarn and an elastic stretch yarn are knitted therein, respectively.
The stretch yarn having an elasticity is knitted into the chain stitch structure in
a stretch state. Consequently, it is possible to give the elasticity to the knitted
lace. Furthermore, the knitted lace is heated after the knitting operation so that
a part of the thermal bonding yarn sticks to the stretch yarn in a portion in which
the thermal bonding yarn and the stretch yarn come in contact with each other. Consequently,
it is possible to prevent the stretch yarn from slippingout of the chain stitch structure.
Thus, it is possible to prevent the stretch yarn from slipping out of the sewing portion,
for example.
Thus, the thermal bonding yarn is knitted into the chain stitch structure. For the
elastic knitted lace, consequently, it is possible to prevent the fray of the yarn.
Also in the case in which the knitted lace repeats an expansion and contraction after
the knitting operation, furthermore, it is possible to prevent each yarn from being
shifted by the thermal bonding yarn. Consequently, the pattern of the knitted lace
in an expansion and contraction can be prevented from being greatly different from
the pattern of the knitted lace before the expansion and contraction. Thus, it is
possible to maintain the sense of beauty of the knitted lace for a long period of
time.
(7) A knitted lace manufactured by the knitted lace fabric.
The knitted lace fabric is heated so that a part of the thermal bonding yarn contained
in the knitted lace fabric is molten and the binding of the respective yarns is strengthened.
Accordingly, it is possible to prevent the fray of the knitted lace formed by using
the knitted lace fabric. Furthermore, the chain stitch structure is formed by using
the chain stitch yarn which is different from the thermal bonding yarn. Consequently,
it is not necessary to thicken the thermal bonding yarn in order to leave the chain
stitch structure. Thus, it is possible to thin the thermal bonding yarn and the chain
stitch yarn. As a result, it is possible to decrease an amount per unit area of the
yarn constituting the ground portion, thereby increasing the difference in the density
of the yarn between the ground portion and the pattern portion.
[0167] Thus, the knitted lace is manufactured by using the knitted lace fabric. Consequently,
it is possible to prevent the fray of the yarn and to increase the difference in the
density of the yarn between the ground portion and the pattern portion, to enhance
a sense of transparency of the knitted lace and to cause the pattern to be clear,
thereby suppressing deterioration in a sense of beauty.
[0168] The invention may be embodied in other specific forms without departing from the
essential characteristics thereof. The present embodiments are therefore to be considered
in all respects as illustrative and not restrictive, the scope of the invention being
indicated by the appended claims rather than by the foregoing description and all
changes which come within the meaning and the range of equivalency of the claims are
therefore intended to be embraced therein.