Technical Field
[0001] The present invention relates to a multilayered knitted fabric. More specifically,
the present invention relates to a multilayered knitted fabric which is highly hygroscopic,
comfortable to wear, not stuffy during slight perspiration due to exercise etc., and
which, even after considerable perspiration, does not make the wearer feel sticky,
wet, or cold because of the sweat, and which has a satisfactory texture and appearance,
as well as a textile product using said knitted fabric such as innerwear, sportswear,
and bedclothes.
Background Art
[0002] Cellulosic materials such as cotton and cupra have excellent hygroscopic and water
absorbing properties, and thus, when used in clothing, generally it is very comfortable
during no (insensible perspiration) or slight perspiration. However, when the amount
of perspiration exceeds about 100 g/m
2 during the summer season or during exercise, cellulosic materials, which can easily
retain the absorbed sweat, tend to make the wearer feel sticky or cold after exercise.
In particular, when the amount of perspiration exceeds about 200 g/m
2, the sticky or coldness becomes severe, making the wearer feel very uncomfortable.
[0003] As a method for preventing discomforts due to such stickiness or coldness, a variety
of fabrics are being investigated that can transfer the sweat from the skin side to
the front side of clothing, so as to leave no moisture on the skin side. Many of them
use hydrophobic fabric at the skin side, and a variety of fabrics have been proposed
including those in which different single yarn fineness and crosssectional shape of
the yarn used are used at the front side and the back side of a knitted fabric.
[0004] For example, the following Patent Document 1 and Patent Document 2 propose knitted
fabrics having a structure in which the front side uses a fiber having an excellent
moisture absorbing ability and the back side uses a fiber having a poor moisture absorbing
ability, thereby controlling the stickiness or coldness.
[0005] Patent Document 1, which uses a fiber having a poor moisture absorbing ability on
the back (skin) side of a knitted fabric, has an insufficient ability of absorbing
sweat. Also, since it uses a staple fiber as one having an excellent moisture absorbing
ability, it has a poor ability of diffusing the absorbed sweat, and thus has an insufficient
ability of reducing stickiness.
[0006] On the other hand, Patent Document 2 uses a cellulose filament as a fiber having
a high moisture absorbing ability and thus has an excellent diffusing ability. However,
since it uses a hydrophobic fiber on the back (skin) side of the knitted fabric, its
ability of absorbing sweat is not sufficient.
[0007] Also, the following Patent Document 3 discloses a knitted fabric having unevenness
provided on the back (skin) side of the knitted fabric, in which a polyester filament
is arranged on the protrusion and a rayon filament fiber on the recess. However, since
the protrusion which comes into contact with the skin is a hydrophobic fiber, its
ability of absorbing sweat is insufficient as for the knitted fabrics described in
Patent Document 1 and Patent Document 2.
[0008] Furthermore, Patent Document 4 discloses a knitted fabric having a hydrophilic fiber
on the back (skin) side thereof. The Patent Document 4 discloses a knitted fabric
having a dry and smooth feel, which is obtained by using a knitted fabric comprising
a hydrophilic fiber and a hydrophobic fiber and making the course density of the back
(skin) side of the knitted fabric greater than that of the front side, thereby imparting
unevenness to the back (skin) side of the knitted fabric.
[0009] However, since the knitted fabric is highly dense and has a very high mixing ratio
of a hydrophilic fiber of 25-75%, the moisture is retained at the skin side, and therefore
despite the presence of unevenness, it has a considerable stickiness, and has an insufficient
skin-dryness to be used in clothing.
[0010] A further example of a wicking fabric is to be found in Patent Document 5.
[0011] Thus, there is still a need for providing a knitted fabric that is not stuffy and
that can control stickiness and coldness, and therefore is comfortable during insensible
perspiration or slight perspiration or even considerable perspiration.
Citation List
Patent Documents
Summary of the Invention
Problems to be Solved by the Invention
[0013] The problem to be solved by the invention is to provide a knitted fabric which is
not stuffy and is comfortable during insensible perspiration or slight perspiration,
which, even after considerable perspiration due to exercise etc., does not make the
wearer feel sticky, wet, or cold because of the sweat, and which has a satisfactory
texture and excellent wear resistance.
Means to Solve the Problems
[0014] After intensive and extensive research and repeated experiments to solve the above
problems, the present inventors have found that by arranging a specific amount of
cellulosic filaments in the vicinity of the surface of the back (skin) side of a knitted
fabric, the above problems can be solved, and thereby have completed the present invention.
[0015] The present invention is a multilayered knitted fabric according to claim 1 with
preferred embodiments according to claims 2 to 6.
Effects of the Invention
[0016] The knitted fabric of the present invention is not stuffy and is comfortable during
insensible perspiration or slight perspiration, which, even after considerable perspiration
due to exercise etc., does not make the wearer feel sticky, wet, or cold because of
the sweat, and has a satisfactory texture and excellent wear resistance, and thus
is preferably used as a knitted fabric for innerwear, sportswear, and bedclothes.
Brief Description of Drawings
[0017]
[Fig. 1] An example of the structural diagram of the knitted fabric of the present
invention.
[Fig. 2] An example of the structural diagram of the knitted fabric of the present
invention.
[Fig. 3] An example of the structural diagram of the knitted fabric of the present
invention.
[Fig. 4] An example of the structural diagram of a conventional knitted fabric.
Mode for Carrying Out the Invention
[0018] The present invention will now be explained in detail below.
[0019] The knitted fabric of the present invention is a fabric that at least comprises 5
to 25% by weight of cellulosic filaments and 75 to 95% by weight of synthetic fibers.
Thus, in the knitted fabric of the present invention, the cellulosic filaments occupy
5 to 25% by weight, preferably 5 to 20% by weight of the overall knitted fabric.
[0020] As used herein, cellulosic filaments include, but not limited to, regenerated cellulosic
filaments such as rayon, cupra and acetate, natural cellulosic filaments such as silk,
and the like. Compared to cellulosic staple fibers such as cotton and regenerated
cellulosic staple fibers, these filaments contain less fluff and have smooth yarn
surface, and thus they have a higher ability of diffusing moisture. Among them, regenerative
cellulosic filaments may be preferred and, among the regenerative cellulosic filaments,
rayon filaments and cupra filaments have a higher moisture content and a higher moisture-absorbing
effect than the original cotton, and thus may be more preferred. Specifically in cupra
filaments compared to rayon filaments, even a single fiber has smooth surface and
thinner fineness, and therefore, when used in a knitted fabric, they are very soft
and have a satisfactory texture, which may be specifically preferred. By arranging
these fibers effectively in a knitted fabric, a knitted fabric that has an excellent
hygroscopic property and excellent effect of reducing stickiness, that is not stuffy
or sticky during insensible perspiration or slight to considerable perspiration, and
is comfortable to wear can be made. When the proportion of cellulosic filaments to
the overall knitted fabric is less than 5%, the knitted fabric has a low hygroscopic
property and a poor ability of absorbing gaseous sweat during insensible perspiration
or slight perspiration, the ability of absorbing and transferring moisture by cellulosic
filaments becomes insufficient, the effect of reducing stickiness during perspiration
cannot be expected, and thus the knitted fabric is not comfortable to wear. On the
other hand, when the content of cellulosic filaments exceeds 25%, stickiness during
perspiration and coldness after perspiration become greater, and thus the knitted
fabric is not comfortable to wear.
[0021] The fineness of cellulosic filaments may preferably be, but not limited to, about
22 to about 84 decitex (dtex), and more preferably about 33 to about 56 dtex. While
the fineness of a single yarn of cellulosic filaments may not be specifically limited,
it may preferably be about 0.5 to about 2 dtex from the viewpoint of feel to the touch
and texture.
[0022] When cellulosic filaments are contained in a knitted fabric, it can be interknitted
with filaments or staple fibers of a polyester- or polyamide-based synthetic fiber.
However, from the viewpoint of treating sweat, it may be preferred that the cellulosic
filaments are arranged in the knitted fabric as a composite yarn with synthetic fibers
such as a polyester- or polyamide-based synthetic fiber, specifically with a synthetic
filaments. When combined, a multifilament yarn may be preferred having a fineness
of the synthetic filaments of about 22 to about 84 dtex, and a fineness of a single
yarn of about 0.5 to about 2 dtex, so as not to ruin softness to the touch. The ratio
of fineness of the cellulosic filaments to the synthetic filaments may preferably
be 1:3 to 2:1. The synthetic filaments may preferably have a modified cross-section
from the viewpoint of treating sweat by diffusion during perspiration. Since a W-shaped
cross-section fiber is a modified and flat shape, it satisfies both of sweat treatment
by capillary action and softness, and therefore may be more preferred.
[0023] Cellulosic filaments or a composite yarn of cellulosic filaments and synthetic filaments
can be arranged by being interknitted with another fiber in the knitted fabric. The
partner yarn of interknitting may preferably be a synthetic filament, specifically
a polyester- or polyamide-based synthetic fiber, and a multifilament yarn may be preferred
having a fineness of a synthetic filament of about 16 to about 170 dtex, and a fineness
of a single yarn of about 0.5 to about 2 dtex. A polyurethane fiber may be interknitted
as appropriate to impart a stretching property to the knitted fabric. A multifilament
yarn for use in the present invention may comprise a delustering agent such as titanium
dioxide, a stabilizer such as phosphoric acid, an ultraviolet absorber such as a hydroxybenzophenone
derivative, a crystal nucleating agent such as talc, a lubricant such as aerosil,
an antioxidant such as a hindered phenol derivative, a flame retardant, an antistatic
agent, a pigment, a fluorescent whitener, an infrared absorber, an antifoaming agent
etc.
[0024] A material for use in the knitted fabric of the present invention can have crimp,
and the crimp extension rate may preferably be 0 to 150% from the viewpoint of softness
to the touch. The crimp extension rate of a false twisted yarn was measured under
the following conditions:
The upper end of a crimped yarn is fixed, a load of 1.77 × 10-3 cN/dt is applied on the lower end, and a length (A) after 30 seconds is measured.
Then, the load of 1.77 × 10-3 cN/dt is removed, a lowad of 0.088 cN/dt is applied, and a length (B) after 30 seconds
is measured. The crimp extension rate is determined from the following formula (1):
[0025] As described above, the knitted fabric of the present invention is a fabric that
at least comprises 5 to 25% by weight of cellulosic filaments and 75 to 95% by weight
of synthetic fibers. Thus, the knitted fabric of the present invention can comprise
fibers other than the cellulosic filaments or the synthetic fibers. However, said
synthetic fibers occupy 75 to 95% by weight, preferably 80 to 95% by weight of the
overall knitted fabric.
[0026] The knitted fabric of the present invention is characterized in that in one surface
A thereof, the proportion of the area occupied by the cellulosic filaments to the
overall area of the knitted fabric in the region of the knitted fabric which ranges
to a depth of 0.13 mm may be 0.2 to 15%, preferably 0.5 to 10%. As used herein, the
region which ranges to a depth of 0.13 mm refers to the outermost layer of surface
A, and this layer comes into direct contact with the sweat on the skin, and absorbs
it. By generating a slantingly arranged structure in which a small amount of cellulosic
filaments in this layer and more cellulosic filaments are arranged in the inner layer
of the knitted fabric, the knitted fabric absorbs sweat faster than the conventional
knitted fabric in which 100% of synthetic fibers is present in the skin side surface
of the knitted fabric, absorbs sweat strongly into the inner layer of the knitted
fabric by slantingly arranged cellulosic filaments, and furthermore sweat is widely
diffused in the knitted fabric without retaining it due to the diffusing property
of cellulosic filaments. Thus, the sweat on the skin can be incorporated quickly and
in large quantities into the knitted fabric, permitting drastic improvement in stickiness
during wearing. Also, since cellulosic filaments also have excellent moisture dispersing
property, moisture dispersion tends to occur in the inner layer, and the dispersed
sweat is released from the skin side to the front side where the humidity is lower.
[0027] In order to slantingly arrange cellulosic filaments from the outermost layer to the
inner layer of a knitted fabric, the relation of the mixing percent X (% by weight)
of cellulosic filaments in the overall knitted fabric and the proportion Y (% by area)
occupied by the cellulosic filaments in the outermost layer is X>Y, preferably (2/3)
·X>Y, and most preferably (1/2) ·X>Y. As used herein, that the proportion occupied
by the cellulosic filaments on the surface of the outermost layer is smaller that
the mixing percent of cellulosic filaments in the overall knitted fabric is rephrased
that cellulosic filaments are slantingly arranged.
[0028] In the relationship between the proportion Yw (% by weight) occupied by the cellulosic
filaments in the outermost layer and X when the specific gravity of cellulosic filaments
is about 1.5, and the specific gravity of synthetic fibers is usually smaller (generally,
the specific gravity of polyester-based fibers is about 1.4, that of polyurethane-based
fibers is abut 1.2, and that of polyamide-based fibers is about 1.1) than that was
considered as well, preferably X>Yw, more preferably (2/3) ·X>Yw, and still more preferably
(1/2) ·X>Yw.
[0029] At this time, Yw can be determined from the following formula (2):
wherein, D
1 denotes the specific gravity of cellulosic filaments, and D
2 denotes an average specific gravity of fibers other than the cellulosic filaments.
[0030] Because, in the knitted fabric of the present invention, a small amount of cellulosic
filaments are arranged in surface A which comes into direct contact with the skin
of the knitted fabric of the present invention, it has excellent feel to the touch.
Also, due to an excellent hygroscopic property, it can control stuffiness.
[0031] In order to further enhance the effect of reducing stickiness of the knitted fabric
of the present invention, it may be preferred to create a knit structure having unevenness
in surface A. The difference in height between the protrusion and the recess may preferably
be about 0.13 to about 0.50 mm. Preferably, the protrusion is evenly distributed in
surface A, and specifically when areas of 1 cm × 1 cm in the sample were measured,
it may be preferred that any one area has 10 or more of the above protrusions, and
the area of the protrusion is about 10 to 70% of the surface area. As a method for
providing unevenness, there can be mentioned a method for devising a knit structure
and introducing a tack structure or needle-drawing structure, a method for stacking
yarns at the protrusions, a method for varying yarn fineness, and the like.
[0032] By providing unevenness on the surface of knitted fabric, degree of coldness to the
touch becomes smaller, and thus when this surface was used as the skin side, stickiness
during perspiration can be further alleviated. When the difference in height between
the protrusion and the recess is less than about 0.13 mm, the area in contact with
the skin is not different from when there is no unevenness, and thus it cannot be
said that there is unevenness, and effect of the knitted fabric of further reducing
stickiness cannot be expected. When the difference in height between the protrusion
and the recess is about 0.13 mm or more, the contact area of the skin and the knitted
fabric becomes smaller when the fabric is worn with the side having unevenness as
the skin side, and thus the effect of reducing stickiness becomes greater when the
knitted fabric absorbed moisture. On the other hand, when the difference in height
between the protrusion and the recess exceeds about 0.50 mm, the thickness of the
fabric becomes great, and thereby rough feel due to unevenness becomes greater leading
to poor wearing feel such as stuffiness due to retention of the air layer.
[0033] Also, if the difference in height between the protrusion and the recess exceeds 0.13
mm, there will be regions which are not included in the region ranging to a depth
of 0.13 mm from the surface. Thus, in this case, surface A can be divided into a region
(hereinafter referred to as the outermost layer of surface A) which ranges to a depth
of 0.13 mm and a region (hereinafter referred to as the inner layer of surface A)
which exceeds a depth of 0.13 mm. The area occupied by the protrusions of the knitted
fabric in the outermost layer of surface A may preferably be 10 to 70% of the total
area of surface A.
[0034] The difference in height between the protrusion and the recess can be determined
by photographing the cross section of a knitted fabric with an electron microscope,
followed by measuring at 5 different sites and averaging. The difference between the
protrusion and the recess of about 0.17 to 0.45 mm may be more preferred.
[0035] By arranging surface A of the knitted fabric of the present invention at the skin
side of the wearer of the textile product, the above-mentioned effect exhibited by
the knitted fabric of the present invention can preferably be expressed.
[0036] The knitted fabric of the present invention is characterized in that the degree of
coldness to the touch (heat transfer coefficient) of surface A when a 200 g/m
2 moisture was imparted is about 180 to about 330 W/m2·°C (W/m
2·k). Said degree of coldness to the touch (hereinafter referred to as the value of
coldness to the touch) may preferably be about 180 to 280 W/m
2·°C, more preferably about 180 to about 260 W/m
2·°C, and more preferably about 180 to about 240 W/m
2·°C.
[0037] In measuring this degree of coldness to the touch, Thermo Labo II manufactured by
Kato Tech Co., Ltd. is used. This instrument measures the amount of heat transfer
when a warmed hot plate is placed on a sample. A specific measuring procedure is as
follows:
[0038] After adjusting the humidity of a sample to be used in measurement for 24 hours in
an environment of 20°C and 65% RH (relative humidity), sampling is carried out at
8 cm × 8cm. A maximum amount of heat transfer is measured at the instant when a hot
plate warmed to 30°C in an environment of 20°C and 65% RH is placed onto a sample
of the knitted fabric placed with surface A facing upward.
[0039] The moisture when a moisture of 200 g/m
2 was imparted is a condition that simulates the amount of moisture in the sweat absorbed
by fabric after an exercise that induces considerable sweating.
[0040] In a method of imparting moisture during measurement, a sprayer may be used to impart
moisture to the surface A side of the sample to a weight of the sample sampled at
8 cm × 8cm of +1.28 g . The temperature of water in the sprayer at this time is 20°C.
[0041] When there is residual water in the knitted fabric, a large amount of heat is taken
from the hot plate, because the thermal conductivity of water is high, and the degree
of coldness to the touch becomes large. Thus, a sample having a large degree of coldness
to the touch means a high stickiness. When the degree of coldness to the touch exceeds
about 330 W/m
2·°C, the stickiness becomes unfavorably large, whereas at a degree of coldness to
the touch smaller than about 180 W/m
2·°C, the stickiness is favorably small, but to attain a degree of coldness to the
touch of less than about 180 W/m
2·°C, unevenness must be markedly large, which is not preferred from the viewpoint
of texture to the touch. While a conventional knitted fabric comprising cellulose
that generally has a large degree of coldness to the touch far exceeding about 330
W/m
2·°C, cellulosic filaments are slantingly arranged in the knitted fabric of the present
invention so as to utilize the water-absorbing and diffusing ability of the cellulosic
filaments, thereby providing a knitted fabric having an improved stickiness even when
a large amount of water was imparted.
[0042] The thickness of the knitted fabric of the present invention may preferably be about
0.5 to about 1.2 mm.
[0043] The thickness of a knitted fabric is measured using a thickness measuring gauge manufactured
by Peacock, in which a measuring part of φ3.0 cm was allowed to come into contact
with a knitted fabric with a 5 g load, and thickness is measured at 3 sites and averaged.
When this thickness is smaller than about 0.5 mm, it has a poor ability of treating
sweat and is not comfortable, whereas when the thickness exceeds about 1.2 mm, roughness
of the fabric becomes large and spoils texture. The thickness of the knitted fabric
of the present invention may more preferably be about 0.5 to about 1.0 mm. According
to the present invention, the sweat on the skin is absorbed quickly by the water-absorbing
and diffusing properties of cellulosic filaments, and thus even a knitted fabric thinner
than those intended to reduce stickiness by the difference of density or fineness
between the front and back of a 100% polyester can exhibit a comparative effect.
[0044] In the knitted fabric of the present invention, surface B opposite to surface A may
be composed mainly of synthetic fibers. Because, when cellulosic filaments are arranged
on the surface of a knitted fabric, broken thread may easily occur due to abrasion
on the front surface side of a textile product during wearing, and interknitting or
difference in color and luster from a composite fiber may easily occur, which can
ruin the appearance. The area occupied by the cellulosic filaments in surface B to
the entire area of the knitted fabric may preferably be 5% or less, more preferably
1% or less, and still more preferably 0.2% or less, and may preferably be smaller
than the proportion of the area occupied by the cellulosic filaments in the region
up to a depth of 0.13 mm in surface A. Most preferably, surface B may be composed
only of synthetic fibers.
[0045] The knitted fabric of the present invention may be warp knitted or weft knitted,
and may preferably have a layered structure of 3 layers or more, having 2 layers of
the front and back layers and an inner layer in between them. Due to restraint of
knitted fabric structure, boundaries between layers may be ambiguous or may be so
as long as it is a knitted fabric that functions equally to 3 layers.
[0046] As a knitting machine for making the knitted fabric of the present invention, there
can be used a flat knitting machine, a double knit circular knitting machine, a tricot
knitting machine, a Raschel knitting machine and the like, and in order to make a
multilayered knitted fabric having 3 layers or more, a double knit circular knitting
machine may be preferred. The knitting gauge used of a knitting machine may preferably
be about 10 to about 40 GG.
[0047] As knitting structure, in the case of double knit circular knitting, for making the
knitted fabric of the present invention, herringbone, blister, waffle, dimple mesh
etc. can be used, and a structure that uses, but not limited to, tuck knitting in
which unevenness can be obtained on the back side of a knitted fabric may be preferred.
In warp knitting, by arranging cellulosic filaments in the middle in three-reed knitting
to produce a structure that expresses unevenness, the desired effect can be exhibited.
The number of loops in the course direction on the front and back of a knitted fabric
of the present invention may not be specifically limited as long as it does not cause
any problems in construction.
[0048] In order to exhibit the effect of reducing stickiness of the knitted fabric of the
present invention, a slantingly arranged structure is effective in which a small amount
of cellulosic filaments are arranged in the outermost layer of surface A of the 3-layered
structure, cellulosic filaments at an amount larger than that in the outermost layer
are arranged in the inner layer of surface A, and synthetic fibers are arranged in
surface B. In this case, for example, by controlling the amount supplied of an interlinked
partner yarn and cellulosic filaments by varying the number of yarn feeding ports
and yarn fineness, cellulosic filaments can be slanted. Also, by using plating knitting
of cellulosic filaments or a composite yarn thereof and synthetic fibers in surface
A of a 2-layer structured knitted fabric, and arranging cellulosic filaments mainly
in the inner layer of surface A of the knitted fabric, there may preferably be used
a method that satisfies the construction of the present invention, if not a 3-layered
structure. There can also be used a method in which, by using cellulosic filaments
or a composite yarn thereof and synthetic fibers in surface A and varying the yarn
fineness to thicken the yarn of synthetic fibers, the cellulosic filaments can be
relatively arranged inside. In this case, the fineness of synthetic fibers in surface
A may preferably be 1.5-times as that of the cellulosic filaments or a composite yarn
thereof.
[0049] The weight of the knitted fabric of the present invention may preferably be, but
not limited to, about 50 to about 300 g/m
2, more preferably about 80 to about 250 g/m
2.
[0050] The knitted fabric of the present invention may preferably be subjected to a moisture
absorption process.
[0051] By making the knitting density of surface B greater than that of surface A of the
knitted fabric of the present invention, a capillary phenomenon can be exhibited to
transfer moisture from the surface A side to the surface B side. By wearing such a
surface A of the knitted fabric of the present invention having a moisture-transferring
function as the skin side of clothing, moisture tends not to remain on the skin surface
even during considerable perspiration, and can alleviate stickiness and coldness during
wearing. Such a knitted fabric can be produced using a different-gauge knitting machine
that has different gauges at the dial side and the cylinder side.
[0052] In order to exhibit a capillary phenomenon, the number of loops in the well direction
of knitted fabric surface B may preferably be made about 1.1 to about 4.5-fold the
number of loops in the well direction of knitted fabric surface A. The number of loops
in the wale direction on the surface may be determined by measuring the number of
knitted loops per width of 2.54 cm (1 inch) with a densimeter, linen tester, or the
like. The number of loops as used herein refers to the number of knitted stitches
identified on each of the front and back of a knitted fabric, and does not include
knitted stitches such as tuck loop or sinker loop.
[0053] In another method for exhibiting a capillary phenomenon, the yarn fineness of the
single yarn on the surface B side is made smaller than that of the single yarn on
the surface A side. Preferably the yarn fineness of the single yarn on the surface
B side is made 1/2 or less that of the single yarn on the surface A side.
[0054] The knitted fabric of the present invention can be used in textile products to be
worn by humans. At this time, by using surface B of the knitted fabric of the present
invention at the outer air side and surface A at the skin side, the above-mentioned
effect can be exhibited.
[0055] The knitted fabric of the present invention may be suitable for, but not limited
to, applications in clothing materials among textile products, for example clothing
for which a sweat treating function is desired such as sportswear and innerwear, can
also be applied in clothing materials for outer wear and lining, bedclothing such
as sheets, and furthermore sanitary articles such as incontinence pants, has comfort
due to the moisture-absorbing property, and exhibits the effect of reducing stickiness
and coldness due to moisture.
Examples
[0056] The present invention will now be explained more specifically below with reference
to examples. The present invention is not limited to them in any way.
[0057] The knitted fabric obtained in examples was evaluated in the following manner.
(1) Area occupied by the cellulosic filaments in surface A.
[0058]
- (i) A knitted fabric sample is immersed in a dye solution containing 1% owf of a direct
dye of an intermediate deep color (such as Sumilight Blue) and 5 g/l of Na2SO4 and heated at 90°C for 30 minutes to stain the cellulosic filament part of the fabric.
The density of the stained sample is adjusted to be equal to that before staining.
- (ii) In the sample from the above (i), 3 areas in a range of 1 cm long × 1 cm wide
are randomly specified, and marked with thread etc. so as to permit three dimensional
identification.
- (iii) The marked areas in surface A of the sample are measured at a measuring interval
of 20 µm using a three dimensional surface profile measuring machine. After correcting
the tilt of the data, the maximum value of height is changed to 20 µm in Excel's contour
map, and the height in which distribution is ubiquitously exhibited in a 1 cm × 1
cm sample is set as the height of the outermost side, from which a two-dimensional
map is created with a value smaller by 0.13 mm as the maximum value of the contour
map to specify the outermost layer part (a region that ranges to a depth of 0.13 mm)
in surface A. As used herein "the height in which distribution is ubiquitously exhibited"
refers to a height in which, when a 1 cm × 1 cm region was divided into four regions
of 5 mm × 5 mm, the surface appears in any of the divided regions. The cellulosic
filaments in the surface of the outermost layer is measured in the following manner.
- (iv) The marked areas in surface A of the same sample are photographed with a microscope,
the data of the above (iii) and (iv) are superimposed, and the area wherein the colored
yarns appear on the surface of the outermost layer in surface A is calculated as an
area occupied by the cellulosic filaments. When the processing of image (iv) is difficult,
the data in the above (iii) and (iv) are printed out in the same size, and after measuring
the weight of paper of a 1 cm × 1 cm area, the two are superimposed, the outermost
layer part is excised, from which the stained yarn part is further excised and the
weight is measured for calculation. The area occupied by the cellulosic filaments
in surface A of the knitted fabric can be calculated in the following equation:
(2) The mixing ratio of cellulosic filaments (% by weight)
[0059] The mixing ratio X of the overall knitted fabric represents an interknitting ratio
of cellulosic filaments of the knitted fabric, and can be calculated from the weight
consumed of the yarn in constructing the knitted fabric, or the weight of cellulosic
filaments measured by decomposing the knitted fabric obtained based on the following
equation (4):
[0060] When the calculation based on the amount of yarn used is difficult, it can be calculated
based on the moisture content of the knitted fabric.
(3) Wearing test
[0061] After a person wearing a shirt prepared so that the back side of the stained knitted
fabric becomes the skin side was placed at rest for 10 minutes in an artificial climate
chamber at an environment of 28°C and 65% RH, the wearer was subjected to a running
exercise for 30 minutes at 8 km/h on a treadmill ORK-3000 manufactured by Ohtake Root
Kogyo Ltd., and then placed at rest for 10 minutes again. Feel to the touch/texture,
comfortable feeling before the running exercise, and stickiness and coldness after
the running exercise were each subjected to sensory rating based on the following
criteria:
<Feel to the touch/texture before the running exercise>
[0062]
A: Good feel to the touch and good texture
B: Slightly bad feel to the touch and slightly bad texture
C: Bad feel to the touch and bad texture
<Comfortable feeling before the running exercise>
[0063]
A: Comfortable
B: Slightly uncomfortable
C: Uncomfortable
<Stickiness after the running exercise>
[0064]
A: Feel no stickiness
B: Feel slight stickiness
C: Feel stickiness
<Coldness after the running exercise>
[0065]
A: Feel no coldness
B: Feel slight coldness
C: Feel coldness
[Working Example 1]
[0066] Using a dual different-gauge circular knitting machine with 18 GG on the dial side
and 24 GG on the cylinder side, a composite yarn (crimp extension rate 7.4%) prepared
by combining a polyester circular cross-sectional yarn of 84dtex/72f, a cupra circular
cross-sectional yarn of 33dtex/24f, and a polyester circular cross-sectional yarn
of 56dtex/72f followed by false twisting, and a yarn (total fineness 336 dtex) prepared
by knitting 4 polyester circular cross-sectional yarns of 84dtex/72f together were
fed as shown in the knitting structure of Fig. 1 (circled numerals in the figure indicate
the order of knitting) to obtain a knitted gray fabric. After this gray fabric was
scoured at 80°C × 20 minutes and washed in a jet dyeing machine, it was preset at
180 × 90 seconds at a tentering rate of 20% using a pin tenter. Thereafter, it was
subjected to polyester staining, a water absorption process and water-washing, and
then extended to a degree in which wrinkles are removed, and final set was carried
out at 150 × 90 seconds to obtain a knitted fabric with a weight of 150 g/m
2 and a thickness of 0.97 mm. At the surface A side of the knitted fabric obtained,
protrusions were present due to difference in fineness of arranged yarns, but the
region (the outermost part) ranging to a depth of 0.13 mm occupied 55% of the area
of the overall knitted fabric. The ratio of area occupied by the cellulosic filaments
at the outermost layer of surface A was 2.5% of the area of the overall knitted fabric,
and the cellulosic filaments were slantingly arranged. The ratio of area occupied
by the cellulosic filaments at the outermost layer of surface B was 0%. The degree
of coldness of surface A when 200 g/m
2 of water was imparted was 195 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it was comfortable
to wear before exercise, and even after perspiration, there was no stickiness or coldness.
The result is shown in Table 1.
[Working Example 2]
[0067] Using a 28-gauge dual gauge circular knitting machine, a composite yarn prepared
by combining a polyester circular cross-sectional yarn of 56dtex/72f, a cupra circular
cross-sectional yarn of 33dtex/24f, and a polyester circular cross-sectional yarn
of 56dtex/72f followed by false twisting, and a polyester circular cross-sectional
yarns of 56dtex/24f were fed as shown in the knitting structure of Fig. 2 (circled
numerals in the figure indicate the order of knitting, and the same yarn type is fed
at the knitting portion indicated on the same line (for example, circled numerals
1 and 13)). When the composite yarn and a polyester circular cross-sectional yarn
of 56dtex/72f were fed, they were subjected to plating so that the composite yarn
is arranged inside of the knitted fabric, and by processing similarly to Working Example
1, a knitted fabric with a weight of 134 g/m
2 and a thickness of 0.69 mm was obtained. At the surface A side of the knitted fabric
obtained, protrusions were present due to yarn overlapping, and the ratio of area
occupied by the cellulosic filaments at the outermost layer of surface A was 4.7%,
and the cellulosic filaments were slantingly arranged. The ratio of area occupied
by the cellulosic filaments at surface B was 0%. The degree of coldness of surface
A when 200 g/m
2 of water was imparted was 220 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it was comfortable
to wear before exercise, and even after perspiration, there was no stickiness or coldness.
The result is shown in Table 1.
[Working Example 3]
[0068] Using a 28 GG tricot knitting machine, a polyester circular cross-sectional yarn
of 56dtex/24f as a structure 10/23 at the front, a polyester circular cross-sectional
yarn of 56dtex/24f and a cupra circular cross-sectional yarn of 56dtex/30f with each
single yarn alternately arranged as structure 21/10 at the middle, and a polyester
W cross-sectional yarn of 56dtex/30f as a structure 10/12 at the back were arranged.
The cupra circular cross-sectional yarn was arranged mainly in the intermediate layer
of the knitted fabric. In a processing treatment similar to Working Example 1, a knitted
fabric with a weight of 138 g/m
2 and a thickness of 0.61 mm was obtained. At the surface A side of the knitted fabric
obtained, unevenness was present in the knitting structure, and the ratio of area
occupied by the cellulosic filaments at the outermost layer of surface A was 9.3%,
and the cellulosic filaments were slantingly arranged. The ratio of area occupied
by the cellulosic filaments at surface B was 0%. The degree of coldness of surface
A when 200 g/m
2 of water was imparted was 255 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it was comfortable
to wear and there was no stickiness or coldness. The result is shown in Table 1.
[Working Example 4]
[0069] Using a 26-gauge dual circular knitting machine, a composite yarn prepared by interlace-combining
a polyester circular cross-sectional yarn of 84dtex/72f, a cupra circular cross-sectional
yarn of 33dtex/24f, and a polyester circular cross-sectional yarn of 56dtex/72f followed
by false twisting, and a polyester circular cross-sectional yarns of 56dtex/24f were
fed as shown in the knitting structure of Fig. 3 (circled numerals in the figure indicate
the order of knitting, and the same yarn type is fed at the knitting portion indicated
on the same line (for example, circled numerals 1, 5 and 9)). When the composite yarn
and a polyester circular cross-sectional yarn of 56dtex/24 were fed, they were subjected
to plating so that the composite yarn is arranged inside of the knitted fabric, and
by processing similarly to Working Example 1, a knitted fabric with a weight of 148
g/m
2 and a thickness of 0.68 mm was obtained. At the surface A side of the knitted fabric
obtained, unevenness was small, and the ratio of area occupied by the cellulosic filaments
at surface A was 4.2%, and the cellulosic filaments were slantingly arranged. The
ratio of area occupied by the cellulosic filaments at surface B was 0%. The degree
of coldness at surface A when 200 g/m
2 of water was imparted was 229 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it was comfortable
to wear before exercise, and even after perspiration, there was no stickiness or coldness.
The result is shown in Table 1.
[Working Example 5]
[0070] Except that the cupra circular cross-sectional yarn of 33dtex/24f in Working Example
2 was replaced with a rayon 84dtex/30f, a knitted fabric similar to that in Working
Example 2 was prepared and a knitted fabric with a weight of 147 g/m
2 and a thickness of 0.78 mm was obtained. At the surface A side of the knitted fabric
obtained, protrusions were present due to yarn overlapping, and the ratio of area
occupied by the cellulosic filaments at the outermost layer of surface A was 9.8%,
and the cellulosic filaments were slantingly arranged. The ratio of area occupied
by the cellulosic filaments in surface B was 5%. The degree of coldness in surface
A when 200 g/m
2 of water was imparted was 273 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it was comfortable
to wear, and there was little stickiness or coldness. The result is shown in Table
1.
[Working Example 6]
[0071] Except that the composite yarn in Working Example 2 was replaced with a cupra circular
cross-sectional yarn of 56dtex/30f and the yarn was fed as shown in the knitting structure
of Fig. 2, conditions similar to that in Working Example 2 were used to obtain a knitted
fabric with a weight of 127 g/m
2 and a thickness of 0.68 mm. At the surface A side of the knitted fabric obtained,
protrusions were present due to yarn overlapping, and the ratio of area occupied by
the cellulosic filaments at the outermost layer of surface A was 13.8%. The ratio
of area occupied by the cellulosic filaments at surface B was 3%. The degree of coldness
in surface A when 200 g/m
2 of water was imparted was 294 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, there was little
stickiness or coldness. The result is shown in Table 1.
[Comparative Example 1]
[0072] Using a 28 GG dual circular knitting machine, a composite yarn prepared by interlace-combining
a cupra circular cross-sectional yarn of 56dtex/24f and a polyester circular cross-sectional
yarn of 56dtex/72f followed by false twisting, and a polyester circular cross-sectional
yarn of 84dtex/72f with each single yarn alternately arranged were knitted as shown
in the knitting structure of Fig. 4. By processing similarly to Working Example 1,
a knitted fabric with a weight of 139 g/m
2 and a thickness of 0.71 mm was obtained. At the surface A side of the knitted fabric
obtained, unevenness was small, and the ratio of area occupied by the cellulosic filaments
at surface A was as large as 18.8%, and the cellulosic filaments were not slantingly
arranged. The ratio of area occupied by the cellulosic filaments at surface B was
18%. The degree of coldness at surface A when 200 g/m
2 of water was imparted was 355 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, there was considerable
stickiness and coldness. The result is shown in Table 1.
[Comparative Example 2]
[0073] Except that all yarns were a polyester circular cross-sectional yarn of 84dtex/72f,
processing similarly to Working Example 1 was carried out to obtain a knitted fabric
with a weight of 126 g/m
2 and a thickness of 0.66 mm. The knitted fabric was 100% polyester, and the degree
of coldness when 200 g/m
2 of water was imparted was 348 W/m
2·°C. In the wearing test of a shirt obtained from this knitted fabric, it lacked comfort
both before and after exercise. The result is shown in Table 1.
[0074] [Table 1]
[Table 1]
|
Feed yarn |
Knitting machine |
Knitting structure |
Weight (g/m2) |
Thickness (mm) |
Mixing ratio (%) |
Cellulose area % of Surface A |
Difference in height of projection and recess (mm) |
Degree of coldness when 200 g/m2 water was given (w/m2·°C) |
Feel & texture before running exercise |
Comfort before running exercise |
Stickiness after running exercise |
Coldness after running exercise |
Surface A |
Surface B |
Cellulose |
Synthetic fiber |
Work. Ex. 1 |
Polyester circular crosssection 84dtex/72f paralleled yarn |
Cupra 33dtex/24f polyester circular crosssection 56dtex/72f composite yarn |
Polyester circular crosssection 64dtex/72f |
|
Dual circular knitting machine |
Fig. 1 |
150 |
0.97 |
8 |
92 |
2.5 |
0.35 |
195 |
A |
A |
A |
A |
Work. Ex. 2 |
Polyester circular crosssection 56dtex/24f |
Cupra 33dtex/24f polyester circular crosssection 56dtex/72f composite yarn |
Polyester circular crosssection 56dtex/72f |
|
Dual circular knitting machine |
Fig. 2 |
134 |
0.69 |
9 |
91 |
4.7 |
0.17 |
220 |
A |
A |
A |
A |
Work. Ex. 3 |
Polyester W shaped crosssection 56dtex/30f |
Cupra 56dtex/30f |
Polyester circular crosssection 56dtex/72f |
|
Tricot |
- |
138 |
0.61 |
17 |
83 |
9.3 |
0.18 |
255 |
A |
A |
A |
A |
Work. Ex. 4 |
Polyester circular crosssection 56dtex/24f |
Cupra 33dtex/24f polyester circular crosssection 56dtex/72f composite yarn |
Polyester circular crosssection 84dtex/72f |
|
Dual circular knitting machine |
Fig. 3 |
148 |
0.68 |
7 |
93 |
4.2 |
0.11 |
229 |
A |
A |
A |
B |
Work. Ex. 5 |
Polyester circular crosssection 56dtex/24f |
Rayon 84dtex/30f polyester W crosssection 56dtex/72f composite yarn |
Polyester circular crosssection 56dtex/72f |
|
Dual circular knitting machine |
Fig. 2 |
147 |
0.78 |
15 |
85 |
9.8 |
0.19 |
273 |
B |
A |
B |
A |
Work. Ex. 6 |
Polyester circular crosssection 56dtex/24f |
Cupra 56dtex/30f |
Polyester circular crosssection 56dtex/72f |
|
Dual circular knitting machine |
Fig. 2 |
127 |
0.68 |
13 |
87 |
13.8 |
0.20 |
294 |
A |
A |
B |
8 |
Comp. Ex. 1 |
Polyester circular crosssection 84dtex/72f |
Cupra 56dtex/24f polyester circular crosssection 56dtex/72f composite yarn |
Polyester circular crosssection 84dtex/72f |
Cupra 56dex/24f polyester circular crosssection 56dtex/72f composite yarn |
Dual circular knitting machine |
Fig. 4 |
139 |
0.71 |
22 |
78 |
18.8 |
0.11 |
355 |
A |
A |
C |
C |
Comp. Ex. 2 |
Polyester circular crosssection 84dtex/72f |
|
Polyester circular crosssection 84dtex/72f |
|
Dual circular knitting machine |
Fig. 2 |
126 |
0.66 |
0 |
100 |
0 |
0.20 |
348 |
C |
C |
C |
C |
Industrial Applicability
[0075] By using the knitted fabric of the present invention, there can be produced a textile
product such as clothing that is not stuffy and is comfortable during insensible perspiration,
and can alleviate stickiness or coldness during slight perspiration or even considerable
perspiration due to exercise for long hours etc. Textile products thus produced such
as sportswear, inner, and outer, and bedclothing etc. are comfortable to wear.