Title of Invention

ELASTIC KNITTED FABRIC HAVING MULTILAYER STRUCTURE AND PROCESS FOR MANUFACTURING THE SAME .

Abstract The invention relates to an elastic fabric having a multilayer structure which is made by binding together separate front and back two-layer ground knitted fabrics (1,2,4,5,7,8,16,17) which are formed by two needle beds, wherein at least one of the ground knitted fabrics form stitches in a state in which polyurethane based elastic fibers (20, 21,22, 23) as a bare string (s) and a non-elastic yarn (6) are arranged and said two-layer ground knitted fabrics are bound with only a polyurethane based elastic fiber bare string (s) of 17 to 3000 decitexes.
Full Text DESCRIPTION
ELASTIC KNITTED FABRIC HAVING MULTILAYER STRUCTURE
AND PROCESS FOR MANUFACTURING THF SAMF
TECHNICAL FIELD
The present invention relates to a circular
elastic knitted fabric having a multilayer structure,
made by binding front and back two ground knitted
fabrics together with a binding yarn, a warp elastic
knitted fabric, a process for manufacturing the same,
and an apparatus for manufacturing the circular elastic
knitted fabric of the present invention. More
particularly, the present invention relates to an
elastic knitted fabric having a three-layer structure
with front and back two ground knitted fabrics bound
together, or a three-dimensional structure having an
air gap between front and back two ground knitted
fabrics. That is, the present invention relates to an
elastic knitted fabric having excellent stretchability,
being dense, light and excellent in shape stability,
being hard to be flattened even under repeated loads in
the case of the three-dimensional elastic knitted
fabric, having excellent compressibility and
compression recoverability, and being excellent in air
permeability and heat retaining property, a process for
manufacturing the same, and a knitting apparatus.

BACKGROUND ART
Traditionally, usual yarns (yarns commonly
used, such as a filament, false twist yarn or spun
yarn) are often used as jointing yarns (binding yarns)
for binding front and back faces together for three-
dimensional structure knitted fabrics made using many
types of weft knitting machines and warp knitting
machines that have been proposed. These are mainly
used for linings and the like of general materials and
cloths, and have an effect of adding appropriate
thermal insulation characteristics, but are poor in
compressibility and compression recoverability.
Furthermore, a three-dimensional structure
knitted fabric using a heat seal yarn as a binding yarn
is known in the art, and examples of the three-
dimensional structure knitted fabrics include a knitted
fabric described in JP-A-4-240252. This knitted fabric
is a mold product utilizing formability of the heat
seal yarn, and is suitable for pressure forming such as
heat press adequate; for the formability, but has almost
no compressibility and compression recoverability, and
flattening resistance or the like under repeated loads
is not considered.
Furthermore, for the example of a knitted
fabric described in JP-A-7-316959, a circular
corrugated knit using a connecting yarn in combination
with a heat seal yarn and a highly crimped yarn is
proposed. Use of polyurethane and the like in the

connecting yarn is described in this publication.
Furthermore, a three-dimensional knitted fabric using a
binding yarn in combination with a heat seal yarn and a
stretchable yarn (polyurethane based elastic fibers,
etc.) is described in JP-A-2001-164444. They are to
provide a cushioning property with the highly crimped
yarn and the stretchable yarn and reduce flattening
under repeated loads, but has a problem such that when
the heat seal yarn is used in the connecting yarn, the
low softening point of the heat seal yarn causes
creases to occur in a substrate during dyeing
processing and the like, the creases are not eliminated
after finishing, and the heat seal yarn as a connecting
yarn is heat-sealed to fix the front and back knitted
fabrics, so that the knitted fabric as a whole has
almost no stretchability, exhibits neither cushioning
property nor flattening resistance by the effects of
the highly crimped yarn and the stretchable yarn, is
poor in compressibility and compression recoverability,
and is flattened under repeated loads. Further, non-
elastic fibers used in the connecting yarn and the
ground knitted fabric are heat-sealed, so that the
knitted fabric as a whole becomes rigid, and although
finding some application for industrial materials, it
is not suitable at all as a general material or sub-
material worn by a person or used at a location close
to a skin, and cannot be practically used in this
field.

On the other hand, as a similar product, a
three-layer structure knitted fabric manufactured by a
double raschel machine, which is one type of warp
knitted fabric, is commercially available. This
knitted fabric uses a monofilament as a binding yarn.
Use of the monofilament is intended for improving the
cushioning property by means of its high degree of
elasticity. However, this three-dimensional structure
knitted fabric is rigid as a whole due to stiffness of
the monofilament, and is therefore unsuitable as a
fabric worn by a person as in the case described above.
JP-A-5-106146 describes a process of
connecting one knitted fabric and the other knitted
fabric with an elastic yarn, and using methods such as
the increasing/decreasing of knitting courses
achievable only by a flatbed knitting machine and
partial knitting to knit a highly rugged and firm
knitted fabric. However, the flatbed knitting machine
has a rough gage, and therefore requires that several
strings of yarn having a large size, for example bulky
wool yarn or highly crimped thick synthetic fiber long
finished yarn should be arranged for knitting, and the
knitted fabric thus formed is a sweater or the like
having rough stitches, and a dense and light knitted
fabric desired in the present invention cannot be
obtained. Furthermore, a stable shape cannot be
retained even when the thickness of the binding yarn is
increased because of the rough gage, and the warp and

weft elongation balance of the knitted fabric is not
satisfactory. Furthermore, the prior art has
technological ideology of a method of three-
dimensionally knitting a fabric along a silhouette of a
human body, but has no concept of providing the knitted
fabric itself with a three-dimensional structure having
an air gap. Further, the flatbed knitting machine has
a fatal problem such that a yarn feeding port travels
to and fro along with a carriage, and a yarn is fed
from the yarn feeding port and a knitting motion is
repeated, but when an elastic yarn is knitted, the draw
ratio varies along the width direction if using a bare
string, thus making it impossible to obtain uniform
stitches. Thus, it is common sense among those skilled
in the art that no bare string is used, but so called a
covering finished yarn with non-elastic fibers
previously wound around a bare string of elastic yarn
is used.
Furthermore, EP Patent Publication No. 431984
describes a knitted fabric for cloths allowing water in
the body to be easily transpired to outside, having two
knitted fabrics connected together with an elastic
yarn, with the back face constituted by water repellent
fibers alone and the front face constituted by water
absorptive fibers and a platting-knitted elastic yarn.
The purpose of using an elastic yarn for the front
knitted fabric is to make stitches of the front knitted
fabric denser to prevent the entrance of the outside

air into the knitted fabric, and the technique is
different from the present invention in both
technological challenge and purpose. In the knitted
fabric having this configuration, curling tends to
occur because the front face and the back face have
different degrees of stretchability, but use of an
elastic yarn for the back face to add stretchability is
not acceptable in view of its purpose. Specifically,
if the elastic yarn is used for the back face to make
the stitches denser in this knitted fabric, water in
the body cannot be transferred through the knitted
fabric, thus making it impossible to transpire water to
the outside. Therefore, in the knitted fabric having
this configuration, occurrence of curling cannot be
inhibited, and a trouble arises in forming the knitted
fabric into a cloth.
Furthermore, traditionally, when a bare
string of polyurethane based elastic fibers is knitted
by a circular knitting machine, all spandex based
elastic fibers on the knitting machine can be fed to
the knitting machine only at a same rate due to
machine-related restriction, and if different weaves
are to be knitted with polyurethane based elastic
fibers, they can be knitted only at the feed speeds
relatively close to each other. As a result,
polyurethane based elastic fibers suffer yarn breakage
due to excessive drawing and fault drawing from a
package of fibers due to insufficient drawing when the

fibers are knitted. Consequently, weave-related
restriction is significant, and knitting conditions are
limited, so that the knitted fabric becomes too dense,
and adequate stretchability cannot be obtained.
DISCLOSURE OF THE INVENTION
An object of the present invention relates to
an elastic knitted fabric having a three-layer
structure with front and back two ground knitted
fabrics bound together, or a three-dimensional
structure having an air gap between front and back two
ground knitted fabrics, and is to provide an elastic
knitted fabric having excellent stretchability, being
dense, light and excellent in shape stability, having a
soft feel, and being most suitable for cloths worn by a
person or used at a location close to the skin, general
materials and sub-materials.
Another object of the present invention is to
provide an elastic knitted fabric being hard to be
flattened under repeated loads in the case of a three-
dimensional structure knitted fabric, having excellent
compressibility and compression recoverability, and
being excellent in air permeability and heat retaining
property, a process for manufacturing the same, and a
knitting apparatus for realizing the same.
That is, the present invention is as follows:
(1) an elastic knitted fabric having a multilayer
structure, made by binding together separate front and

back two-layer ground knitted fabrics, wherein the
above described two-layer ground knitted fabrics are
bound with only a polyurethane based elastic fiber bare
string(s) of 17 to 3000 decitexes;
(2) the elastic knitted fabric of (1), wherein
the above described elastic knitted fabric is a
circular knitted fabric with the separate front and
back two-layer ground knitted fabrics each formed by
one needle bed, the two-layer ground knitted fabrics
are bound together by a tuck loop with only a binding
yarn(s) constituted by a polyurethane based elastic
fiber bare string(s) of 33 to 3000 decitexes, the
binding yarn is bound to 25% or more of stitches of one
of the front and back ground knitted fabrics having a
lower stitch density, the ratio of the loop length of
the binding yarn to the loop length of any one of the
above described separate front and back circular
knitted fabrics having a smaller loop length is in a
range of 0.6 to 2.3, and the elastic knitted fabric has
an air gap between the front and back ground knitted
fabrics, and has a three dimensional structure;
(3) the elastic knitted fabric of (1), wherein
the above described elastic knitted fabric is a
circular knitted fabric with the separate front and
back two-layer ground knitted fabrics each formed by
one needle bed, the two-layer ground knitted fabrics
are bound together with only a binding yarn(s)
constituted by a polyurethane based elastic fiber bare

string(s) of 17 to 1500 decitexes, at least one of
ground knitted fabrics are bound by a tuck loop to the
binding yarn, the binding yarn is bound to 25% or more
of stitches of one of the front and back ground knitted
fabrics having a lower stitch density, the ratio of the
loop length of the binding yarn to the loop length of
any one of the above described separate front and back
weft knitted fabrics having a smaller loop length is in
a range of 0.2 to 0.6, and the elastic knitted fabric
has a three-layer structure; and
(4) the elastic knitted fabric of (1), wherein
the above described two-layer ground knitted fabrics
each has a warp-knitted structure, and the above
described binding yarn is bound to 25% or more of
stitches of one of the front and back ground knitted
fabrics having a lower stitch density.
The elastic knitted fabrics described above
may contain polyurethane based elastic fibers in the
ground knitted fabrics. The inventors have devised an
apparatus for changing a feed speed of spandex based
elastic fibers on a knitting machine, and found a
manufacturing process using the apparatus, thereby
making it possible to provide an elastic knitted fabric
having excellent stretchability, and being dense, light
and excellent in shape stability, having a soft feel,
and being most suitable for cloths worn by a person or
used at a location close to the skin, general materials
and sub-materials, which has not been achieved in the

prior art. Thus, the inventors completed the present
invention.
BRIEF DESCRIPTION OF THE/DRAWINGS
FIG. 1 is a loop diagram of a three-
dimensional structure of the present invention;
FIG. 2 is a loop diagram of a three-layer
structure of the present invention;
FIG. 3 is a loop diagram of a Russell
structure of the present invention;
FIG. 4 is an outline drawing of a feeding
apparatus for elastic yarn of the present invention;
FIG. 5 is a holder side view of the feeding
apparatus for elastic yarn of the present invention;
FIG. 6 is a holder front view of the feeding
apparatus for elastic yarn of the present invention;
FIG. 7 shows a photographed cross section of
the three-dimensional structure of the present
invention; and
FIG. 8 shows a photographed cross section of
the three-layer structure of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
The present invention will be described in
detail below.
In an elastic knitted fabric having a
multilayer structure of the present invention, front
and back ground knitted fabrics denoted by reference

numerals 16 and 17 in FIGs. 1 and 7 and reference
numerals 18 and 19 in FIGs. 2 and 8 are independently-
formed, and a binding yarn for binding the above
described both ground knitted fabrics, denoted by
reference numeral 3 in FIG. 1 and reference numeral 6
in FIG. 2, is made by only a bare string (s) of
polyurethane based elastic fibers. The binding yarn
for binding both the ground knitted fabrics is a bare
string of polyurethane based elastic fibers, so that
excellent stretchability can be added to a bound
elastic knitted fabric having a multilayer structure
without restricting elongation in warp and weft
directions. The size of the bare string of
polyurethane based elastic fibers for use in the
present invention is 17 to 3000 decitexes.
Further, for describing a preferred aspect of
the present invention, an elastic knitted fabric of
such a preferred aspect consists of the following three
structures.
For the first preferred structure, separate
front and back ground knitted fabrics are each
independently formed by each needle bed of a circular
knitting machine having two needle beds as shown in a
loop structure diagram in FIG. 1. Both the ground
knitted fabrics are bound together with only a bare
string(s) of polyurethane based elastic fibers but in
this case, the binding yarn is bound by a tuck loop to
at least one of the ground knitted fabrics. By

increasing the feed speed of the binding yarn, a three-
dimensional structure having an air gap between front
and back two ground knitted fabrics is formed. The
binding yarn denoted by reference numeral 3 in FIG. 1
is bound to 25% or more of stitches of one of the front
and back ground knitted fabrics having a lower stitch
density, the ratio of the loop length of the binding
yarn made of polyurethane based elastic fibers to the
loop length of any one of the above described separate
front and back circular knitted fabrics having a
smaller loop length is in a range of 0.6 to 2.3. This
is because by making the ratio of the loop length of
the binding yarn to the loop length of the ground
knitted fabric relatively large, the front and back two
ground knitted fabrics are bound together with
polyurethane based elastic fibers to form a three-
dimensional structure having an air gap therein as
shown by reference numeral 3 in FIG. 7. If this ratio
(T) is smaller than 0.6, a problem may arise in terms
of compressibility, recoverability and knitting
characteristics of the obtained three-dimensional
knitted fabric. The ratio (T) is preferably equal to
or smaller than 2.3 in obtaining a three-dimensional
knitted fabric having a good feel, and if the ratio is
greater than 2.3, a bare string of polyurethane based
elastic fibers may protrude from the front and back
knitted fabrics to compromise the quality of the
knitted fabric. In the present invention, the binding

of ground knitted fabrics with a bare string of
polyurethane based elastic fibers is performed by tuck
knitting with at least one of the front and back ground
knitted fabrics, but as for the number of bindings, the
string is preferably bound to 25% or more of stitches
of one of the front and back ground knitted fabrics
having a lower stitch density.
The size of a bare string of polyurethane
based elastic fibers to be used is preferably in a
range of 33 to 3000 decitexes, more preferably 70 to
2000 in terms of the three-dimensional shape retaining
property, recoverability from compression and
resistance to flattening by repeated fatigues. If the
size is smaller than 33 decitexes, the three-
dimensional shape cannot be retained in the three-
dimensional structure elastic knitted fabric of the
present invention with a weak shearing force, and it
may be impossible to obtain satisfactory recoverability
from compression. If the size increases to more than
3000 decitexes, the weight of the elastic knitted
fabric itself may become too large for use in cloths
and the like.
Furthermore, the break elongation of the bare
string of polyurethane based elastic fibers is
preferably 400 to 1100%, and the dry heat processing
temperature for presetting or the like during dyeing is
preferably around 190°C so that stretchability is not
compromised.

In the present invention, for the method for
binding ground knit fabrics with a bare string(s) of
polyurethane based elastic fibers, one side may be
bound by a tuck loop and the other side may be bound by
a knit loop, but both the ground knitted fabrics are
preferably tuck-bound for obtaining a stretchable
knitted fabric having a bare string(s) of polyurethane
based elastic fibers bound without affecting front and
back knitted fabrics, allowing promotion of reduction
in the thickness of the ground knitted fabric, having
excellent elongation recoverability, having a good
feel, and being excellent in form stability and surface
quality.
Furthermore, if non-elastic fibers are
contained in a binding yarn for binding front and back
ground knitted fabrics together, compressibility or
compression recoverability and the feel are
compromised.
The method for knitting a bare string(s) of
polyurethane based elastic fibers for use as a binding
yarn is not limited, but for obtaining good fabric
thinness feeling and elongation recoverability, zigzag
binding in which the binding ratio of the ground
knitted fabric to the number of stitches is 50% is
preferable because an appropriate air gap is retained
between front and back ground knitted fabrics and the
three-dimensional shape is excellently retained.
Furthermore, it is preferable that both the ground

knitted fabrics are tuck-bound and the number of
bindings to the front weave equals the number of
bindings to the back weave because the surfaces of the
front and back ground knitted fabrics of the elastic
knitted fabric are flattened.
The term "having a three-dimensional
structure" in the present invention means that front
and back two ground knitted fabrics are substantially
in a non-contact state, and the front and back two
ground knitted fabrics are column-wise supported by a
bare string(s) of polyurethane elastic fibers to retain
an air gap between the two ground knitted fabrics.
An example of a process for manufacturing an
elastic knitted fabric having a three-dimensional
structure of the present invention will now be
described.
As a knitting machine, the so-called double
knit circular knitting machine having a normal two-row
needle bed, which preferably has a large number of yarn
feeding ports and a feeder capable of feeding a
plurality of strings at a time, is preferably used.
The gage of the knitting machine may be selected as
appropriate according to an intended purpose, but a 18
to 40 gage knitting machine is usually used. Other
than the gage double knit circular knitting machine,
for example, a 42 gage knitting machine may be used as
a 21 gage-equivalent machine with a needle being drawn
out on one-by-one basis. Furthermore, a circular

knitting machine having a gage rougher than the 18 gage
may be used but in this case, it is preferable that a
bed having a gage rougher than the 18 gage is limited
to one of a dial bed and a cylinder bed, and the other
bed has a 18 gage or higher for obtaining a dense and
light knitted fabric desired in the present invention.
The thickness of the yarn used in front and
back knitted fabrics, and denoted by reference numerals
1 and 2 in FIG. 1 and reference numerals 4 and 5 in
FIG. 2 is not specifically limited, but the gross size
is preferably in a range of 22 to 1220 decitexes, more
preferably 34 to 310 decitexes. The size of a single
yarn is preferably in a range of 0.1 to 610 decitexes,
more preferably 1 to 100 decitexes.
The front and back ground knitted fabrics are
not specifically limited, but they are preferably
knitted weaves formed by one needle bed of a circular
knitting machine, and are for example basic weaves of
plain knitting, and derivative weaves of tuck knitting,
float knitting, half cardigan stitch, lace knitting,
platting knitting and the like.
As shown in the loop structure diagram in
FIG. 2, a second preferred structure in the present
invention has a knitted weave similar to that of the
first structure described above, but is characterized
in that the binding yarn is bound to 25% or more of
stitches of one of the front and back ground knitted
fabrics having a lower stitch density, and the ratio of

the loop length of the binding yarn constituted by
polyurethane based elastic fibers to the loop length of
one of the above described separate front and back
circular knitted fabrics having a smaller loop length
is 0.2 to 0.6. The ratio of the loop length of the
binding yarn constituted by polyurethane based elastic
fibers to the loop length of the ground knitted fabric
consisting of a circular knitted structure is
relatively small, and the front and back two ground
knitted fabrics are bound together with polyurethane
based elastic fibers to form a three-layer structure.
In this case, the size of a bare string of polyurethane
base elastic fibers to be used is preferably in a range
of 17 to 1500 decitexes, more preferably 22 to 640
decitexes in terms of stretchability, the surface
quality of the knitted fabric.
Furthermore, the break elongation of the bare
string of polyurethane based elastic fibers is
preferably 400 to 1100%, and the dry heat processing
temperature for presetting or the like during dyeing is
preferably around 190°C so that stretchability is not
compromised. Furthermore, in the present invention,
the ratio of the loop length of the bare string of
polyurethane based elastic fibers as a binding yarn to
the loop length of one of front and back weft knitted
fabrics having a smaller loop length, specifically the
ratio to either the: loop length of cylinder stitches
constituting one face or the loop length of dial

stitches constituting the other face, which is smaller,
is preferably 0.2 to 0.6, more preferably 0.2 to 0.5.
If the ratio of the loop length of the bare string of
polyurethane based elastic fibers is smaller than 0.2,
the elongation of elastic fibers in the knitted fabric
increases, so that yearn breaking and degradation in
the surface quality of the substrate occurs during
knitting, and elastic fibers are easily drawn out of
the end surface of the knitted fabric, and a problem
may arise if it is repeatedly worn and elongated as a
cloth. If the ratio of the loop length is greater than
0.6, front and back knitted fabrics cannot be brought
into close contact with each other, so that the fabric
thinness is degraded, and the elongation of elastic
fibers in the substrate drops so that elongation
recoverability may be compromised. The ratio of the
loop length described herein refers to the ratio of the
length L-c in a relaxed state of the binding yarn to
the length L-g of a yarn constituting the ground
knitted fabric equivalent to one course deknitted and
taken out from the knitted fabric having a fixed width
(L-c/L-g).
In this structure, the binding of ground
knitted fabrics with a bare string(s) of polyurethane
based elastic fibers is performed by tuck-knitting with
at least one of the front and back ground knitted
fabrics. As for the number of bindings, the string is
bound to 25% or more of stitches of one of the front

and back ground knitted fabrics having a lower stitch
density. For obtaining satisfactory fabric thinness
feeling and elongation recoverability, zigzag binding
in which the binding ratio of the ground knitted fabric
to the number of stitches is 50% is superior and
preferable. Furthermore, it is preferable that the
binding of the binding yarn to both the front and back
ground knitted fabrics is tuck binding, and the number
of bindings to the front ground knitted fabric equals
the number of bindings to the back ground knitted
fabric because the appearance of a flat elastic knitted
fabric is obtained.
A third preferred structure in the present
invention is a multilayer elastic warp knitted fabric
made by binding together separate front and back ground
knitted fabrics, characterized in that the above
described two-layer ground knitted fabrics consist of a
warp knitted structure, the ground knitted fabrics are
bound with only a bare string(s) of polyurethane based
elastic fibers of 17 to 3000 decitexes, and the binding
yarn is bound to 25% or more of stitches of one of the
front and back ground knitted fabrics having a lower
stitch density.
One example of the elastic warp knitted
fabric of the present invention is shown in FIG. 3.
The elastic warp knitted fabric can be knitted by a
warp knitting machine having a two-row needle bed.
That is, front and back two ground knitted fabrics 7

and 8 of the elastic warp knitted fabric having a
multilayer structure, of the present invention, has a
warp knitted structure, and may be any of a chain-
knitted fabric, a 1x1 tricot stitch fabric, a cord-
knitted fabric, a mesh-knitted fabric and the like. It
may be a combination of a broad stitch with the front
knitted fabric and the back knitted fabric. The ground
knitted fabrics can be connected together with only a
bare string(s) of polyurethane based elastic fibers 9
to obtain the elastic warp knitted fabric of the
present invention.
In the present invention, the binding of
ground knitted fabrics with a bare string (s) of
polyurethane basesd elastic fibers may be knit loop
binding or may be tuck loop binding. The former is
preferable in the case of the three-layer warp knitted
structure having a shape with front and back ground
knitted fabrics bound together, and any of knit loop
binding and tuck loop binding may be employed in the
case of the three-dimensional structure having an air
gap between front and back ground knitted fabrics. For
the number of bindings, the binding yarn is bound to
25% or more, preferably 50% or more, of stitches of one
of front, and back ground knitted fabrics having a lower
stitch density.
The size of a bare string of polyurethane
based elastic fibers to be used is preferably in a
range of 33 to 3000 decitexes, further preferably 70 to

2000 decitexes in terms of the three-dimensional shape
retaining property, recoverability from compression,
resistance to flattening by repeated fatigues, and the
like. If the size is smaller than 33 decitexes, the
three-dimensional shape cannot be retained in the
three-dimensional structure elastic knitted fabric of
the present invention with a weak shearing force, and
satisfactory recoverability from compression cannot be
obtained. If the size increases to more than 3000
decitexes, the weight of the elastic knitted fabric
itself becomes too large for use in cloths and the
like.
In the present invention, at least one of
front and back ground knitted fabrics preferably
contains an elastic composite yarn for further
improving the elastic knitted fabrics having the
multilayer structures of the three types described
above and meeting the object. The elastic composite
yarn described here refers to yarns with polyurethane
based elastic fibers and non-elastic yarns combined in
a variety of ways, which include, for example, a
composite yarn covering-processed, for example, with
polyurethane based elastic fibers as a core and
polyamide long fibers as a sheath, and a core spun yarn
using polyurethane based elastic fibers as a core
surrounded by short fibers such as cotton to form a
spun yarn.
By incorporating an elastic composite yarn in

at least one of front and back ground knitted fabrics,
stretchability can be added to the multilayer elastic
knitted fabric of the present invention.
Stretchability in the width direction of the knitted
fabric by the binding yarn is supplemented, and
stretchability can be also added in the length
direction of the knitted fabric, so that a multilayer
structure elastic knitted fabric having satisfactory
stretchability in both warp and weft directions is
provided. By making the stitch of the ground knitted
fabric smaller and denser with a elongation recovery
force of the elastic yarn, the connection yarn can be
tightly bound thereto, thus making it possible to
provide a stable multilayer structure. Furthermore, if
the density of the entire ground knitted fabric is
increased with the elastic yarn, the density of the
connecting yarn is also increased, and a binding angle
between the ground knitted fabric and the connecting
yarn becomes closer to a right angle in the case of the
elastic knitted fabric having a three-dimensional
structure, resulting in an improvement in compression
resilience and recovery rate.
If the elastic composite yarn is knitted into
one of front and back two ground knitted fabrics, the
above-described effect can be obtained. It is
preferable that the composite yarn is knitted into both
the ground knitted fabrics, because the balance of the
knitted fabric is improved in the front and back

fabrics, and phenomena such as the so-called curling
such that the ear part or end part of the knitted
fabric is curled up can be eliminated. Furthermore,
the elastic composite yarn may form the ground knitted
fabric by itself, may be arranged with another non-
elastic yarn to form stitches, or may be cross-knitted
with the non-elastic yarn.
In the elastic knitted fabric having a
multilayer structure, of the present invention, the
case will be described where both front and back ground
knitted fabrics contain polyurethane based elastic
fibers as a bare string(s), and the bare string(s) of
polyurethane based elastic fibers and the non-elastic
yarn are arranged to form stitches. In this case, like
the elastic knitted fabric containing the elastic
composite yarn, stretchability can be added to the
multilayer elastic knitted fabric. Stretchability in
the width direction of the knitted fabric by the
binding yarn can be supplemented, and stretchability
can also be added in the long direction of the knitted
fabric, so that a multilayer structure elastic knitted
fabric having satisfactory stretchability in both warp
and weft directions is provided. By making stitches of
the ground knitted fabric smaller and denser with a
elongation recovery force of the elastic yarn, the
density of the binding yarn is increased, and a
crossing angle (binding angle) between the ground
knitted fabrics 16 and 17 and the binding yarn 3

of the entire knitted fabric.
The bare string of polyurethane elastic yarn
described herein is a yarn produced in such a manner
that a spinning stock solution is extruded into a
spinning chamber through one or more spinnerets,
i
converged and fusion-bound in contact sites of single
strings, for example, and wound up in a state of a
monofilament on the surface, and a covered elastic yarn
with the bare string covered with a non-elastic fiber
multifilament or the like, and a core spun yarn spun
with short fibers such as cotton are exceptions.
The content of polyurethane based elastic
fibers (denoted by reference numerals 20 and 21 in FIG.
1 and reference numerals 22 and 23 in FIG. 2, although
those denoted by reference numerals 21 and 23 in the
figures cannot been seen behind the non-elastic yarn)
in front and back two ground knitted fabrics is
preferably not less than 2% and not more than 60%, more
preferably not less than 4% and not more than 20%,
based on the non-elastic yarn in the same knitted
fabric. As the content of polyurethane based elastic
fibers decreases, a stretch performance of the entire
knitted fabric is reduced. If the content of elastic
yarn is less than 2%, the amount of elastic yarn is so
small that the stretch performance of the entire
knitted fabric may be reduced. Therefore, sufficient
stretchability is hard to be added to the entire
knitted fabric, and if the content is greater than 60%,

becomes closer to 90°, thus making it possible to
improve the compression resilience and recovery rate of
the elastic knitted fabric having a three-dimension
structure.
By using a bare string of polyurethane
elastic yarn as a binding yarn, the fiber pack density
of a binding site located in the middle of the three-
dimensional structure drops so that a space expands.
That is, the bare string(s) of polyurethane elastic
yarn is formed into a monofilament in such a manner
that several single strings are fusion-bound, and
therefore a space in the air gap of the binding site is
large. On the other hand, in the case of a composite
elastic yarn using the polyurethane elastic yarn as a
core, covered with mono or multi-non-elastic fibers,
the composite elastic yarn itself thickens, or covering
fibers expands in. a connecting site with
expansion/contraction of the polyurethane elastic yarn
and as a result, a space in the air gap is lessened.
By using a bare string of polyurethane elastic yarn as
a binding yarn, the air permeability of the entire
knitted fabric is considerably improved, and weight
saving can be achieved. Further, by using a bare
string of polyurethane elastic yarn as a connecting
yarn, the contact area of connecting yarns decreases in
the connecting site, and thus the heat conductivity
drops, and a large amount of air layer is contained,
resulting in an improvement in heat retaining property

the density of the knitted fabric becomes so high that
the mass per unit area may excessively increase to
compromise the air permeability. If the content of
elastic yarn is not less than 4% and not more than 20%,
an optimum knitted fabric having stretchability, being
soft and having an appropriate tension and drape
property can be obtained.
If formation of stitches with the bare string
of polyurethane based elastic fibers in the ground
knitted fabric is continuous, plain-knitted weaves are
formed with the bare string but in this case, bare
strings contact each other at a contact point of
stitches in a loop-nodal manner, and the ground knitted
fabric is heat-sealed in set processing during refine
dye-finishing and dyeing, and thus the so-called run
such that stitches are deknitted from the end of the
substrate never occurs even if the ground knitted
fabric is knitted by plain knitting or chain knitting.
Further, the binding yarn contacts the bare string of
polyurethane; based elastic fibers at a nodal site of
the binding yarn and the ground knitted fabric, and if
refine dye-finishing is similarly performed in this
state, the above described contact site is heat-sealed
in dry heat setting and wet heat processing during
dyeing. In this case, the knitted fabric is free from
a weave shift and stable even if the entire knitted
fabric is distorted and stressed. In the case of the
elastic circular knitted fabric having a three-

dimensional structure, a resilient force of
polyurethane is transmitted quickly throughout the
knitted fabric to improve the instant resilience of the
knitted fabric. In the case of the elastic circular
knitted fabric having a three-dimensional structure,
the resilience from compression along the thickness of
the three-dimensional structure is improved, and
deformation can be endured to recover the original
shape even under a shearing force because the ground
knitted fabric and the polyurethane based elastic
fibers of the binding yarn are fusion-bound together in
front and back ground knitted fabrics. Further, when a
knitted fabric is formed into a cloth, it has been
conventionally required that the ends of the knitted
fabric are sewn together by a sewing machine or the
like. However, the knitted fabric of the present
invention can be used for a cloth in a cut state
because the polyurethane fibers of the ground knitted
fabric and the binding yarn are fusion-bound together.
In this case, the bare string of polyurethane elastic
yarn should be knitted into both front and back ground
knitted fabrics. Further, for the problem such that
the binding yarn easily falls out from the stitch due
to expansion/contraction at the time of wearing the
knitted fabric, the bare string of polyurethane elastic
yarn is preferably knitted into the ground knitted
fabric, and further preferably into both the ground
knitted fabrics. In this way, the bare string of

polyurethane based elastic fibers is knitted into the
front and back two ground knitted fabrics, resulting in
many advantages given to the elastic circular knitted
fabric having a three-layer structure and the elastic
circular knitted fabric having a three-dimensional
structure. Here, if a non-elastic heat seal yarn and
thermoplastic synthetic fibers such as polyester are
heat-sealed in the three-dimensional structure, the
entire knitted fabric is hardened, and bending rigidity
increases, so that the knitted fabric can hardly be
worn by a person or used at a location close to the
skin, as described previously. However, if
polyurethane elastic fibers are fusion-bound together,
a binding point is fixed, but the yarn itself expands
and contracts, and therefore the knitted fabric as a
whole has stretchability, is soft and has an
appropriate tension and drape.
The case will now be described where only one
of front and back ground knitted fabrics has
polyurethane based elastic fibers as a bare string and
a non-elastic yarn arranged to form stitches, and both
the ground knitted fabrics are bound together with the
bare string(s) of polyurethane based elastic fibers.
In this case, since the front and back knitted fabrics
have different expansion/contraction powers, and the
expansion/contraction power of the ground knitted
fabric containing polyurethane based elastic fibers is
greater than that of the other ground knitted fabric, a

problem arises such that curling of the substrate
occurs with the ground knitted fabric of greater
expansion/contraction power being inside, thus making
it impossible to obtain a practical elastic knitted
fabric. Particularly, this disadvantage occurs in the
three-dimensional structure elastic circular knitted
fabric, but is especially significant in the three-
layer elastic circular knitted fabric. Thus, when the
bare string of polyurethane based elastic fibers in one
ground knitted fabric is knitted, the size of the
binding yarn should be greater than the size of
polyurethane based elastic fibers of the ground knitted
fabric for alleviating the unbalance of knitted fabric
expansion/contraction powers. The present inventors
have conducted vigorous studies on this problem, and
found that if the ratio (D-c/D-g) of the size (D-c) of
binding polyurethane based elastic fibers to the size
(D-g) of polyurethane based elastic fibers in the
ground knitted fabric is 2 or greater, curling of the
substrate is alleviated, and the ratio of 3 or greater
is further preferable, thus making it possible to
provide a three-layer structure elastic circular
knitted fabric capable of being practically used.
The compression performance and the
compression recoverability of the elastic circular
knitted fabric and the elastic warp knitted fabric
having a three-dimensional structure, of the present
invention, vary depending on the thickness of the

elastic knitted fabric and the size of the elastic yarn
used for the binding yarn 3. That is, as the size of
the elastic yarn used for the binding yarn 3 increases,
the compression performance and the compression
recoverability are improved, while as the thickness of
the elastic knitted fabric increases, the compression
performance and the compression recoverability are
reduced.
In the present invention, a ratio between the
gross size (D) (decitex) of the binding yarn 3 bound in
any area of 1 cm2 in the ground knitted fabric and the
thickness (T) (mm) of the knitted fabric of the area
preferably meets the requirement of 5 x 103 105. If 5 x 103 > D/T holds, it may be impossible to
achieve a sufficient improvement in compression
performance and compression recoverability, while if
D/T > 5 x 105 holds, the compression resistance and the
bending rigidity of the entire knitted fabric tend to
increase, so that generally, use by a person around his
or her body may involve some difficulty.
In the case of the elastic circular knitted
fabric having a three-dimensional structure, the
binding yarn is bound to the stitch of the ground
knitted fabric by tuck knitting. In the case of the
elastic warp knitted fabric having a three-dimensional
structure, the binding yarn is bound to the stitch of
the ground knitted fabric by knit sewing and/or tuck
knitting. The rate (R) of stitches bound to the

connecting yarn, of stitches in an area of 1 cm2 at any
site of front and back two ground knitted fabrics, is
preferably 25% or greater. If the rate (R) of the
stitches is less than 25%, the number of strings of
connecting yarn decreases, so that it may be impossible
to obtain a sufficient resilience and recovery rate.
By increasing the size of the connecting yarn to be
used, the compression resilience and recoverability are
improved, but irregularities may occur on the surface
of the ground knitted fabric due to the connection to
compromise the flatness of the surface of the
substrate.
Except for the case where the connecting yarn
and the ground knitted fabric are bound at all
stitches, the pattern in which the connecting yarn is
connected to the stitch of the ground knitted fabric is
different for each of any courses. However, for
example, if the ground knitted fabric is connected to
the connecting yarn at odd-number stitches in an
alternate manner in any course, and the ground knitted
fabric is connected to the connecting yarn at even-
number stitches in an alternate manner in the next
course, the surface of the ground knitted fabric
becomes uniform, and the compression resilience and
recovery rate become uniform for each knitted fabric
site, which is preferable. The phase of the connecting
site is shifted for each knitting course, and this is
repeated to obtain a satisfactory knitted fabric.

Then, as a result of conducting vigorous
studies on elongation characteristics of the substrate
following the elongation of the skin associated with a
motion of a person, the present inventors have found
the elastic knitted fabric having a multilayer
structure according to any one of claims 5, 6 and 7,
characterized in that the elongation in each of warp
and weft directions is 80 to 150% under a load of 3.5
N/cm, and 100 to 200% under a load of 9.8 N/cm, an
elongation ratio (A) and an elongation ratio (B) in
warp and weft directions, expressed by the following
equations (1) and (2), are both in a range of 0.8 to
1.2.
Elongation ratio (A) = elongation (%) in warp
direction under load of 3.5 N/cm -i- elongation in weft
direction (%) (1)
Elongation ratio (B) = elongation (%) in warp
direction under load of 9.8 N/cm H- elongation in weft
direction (%) (2)
That is, the present inventors have found
that a stress in the elongation direction when the
motion of the person along the body height is followed
to elongate the substrate and a stress of the substrate
in the circumference direction of the human body
significantly affect the wear feeling; and if a
predetermined elongation is provided in both warp and
weft directions of the knitted fabric, an elastic
knitted fabric excellent in motion following

characteristics and detachability and comfortable for
wearing can be obtained; and by inhibiting an
unnecessary elongation of the substrate, durability of
the substrate can be improved. Thus, the present
inventors achieved the present invention.
The elongation described above refers to a
value measured with a monoaxially fixed biaxial tensile
tester (STRIP BIAIAL TENSILTESTER KES-G2-SB1
manufactured by Kato Tech Co., Ltd.). The substrate is
restrained in one direction and the substrate
elongation in the other direction is measured, thus
making it possible to measure the elongation for
practical use. Incidentally, since the conventional
elongation measurement method is such that a
measurement is made with only the elongation direction
fixed and other directions not restrained, it has a
disadvantage that the substrate width changes at the
middle of the grip, thus making it impossible to
measure a change in stress in two directions covering
the cloth width at the time of wearing.
The load of 3.5 N/cm according to the present
invention corresponds to the power with which a person
of average power may pull the fabric when he or she
wears it. The feeling of the soft power or hard power
in the circumference direction of the person varies
depending on product concepts and personal preferences,
but if the elongation in the warp direction of the
elastic knitted fabric under the load of 3.5 N/cm is

less than 80%, elongation of the substrate is generally
insufficient, thus requiring an excessive force for
wearing and taking off the fabric. On the other hand,
if the elongation in the weft direction is less than
80%, one feels strained because the skin elongation in
the elongation direction in a lie motion is maximum
50%, and if the fabric is worn as a girdle,
unpleasantness is brought about such that a waist line
or the lower end of the femor is shifted. Furthermore,
if the elongation in each of warp and weft directions
of the elastic knitted fabric is greater than 200%
under the load of 3.5 N/cm, expansion/contraction
fatigues of the elastic yarn become so significant that
durability is compromised and the strength of the
substrate is reduced.
The load of 9.8 N/cm corresponds to the
utmost extended elongation of the substrate and to the
power causing an accident of breaking through the
substrate by a consumer. For preventing such an
accident, the utmost extended elongation should be
reduced to 200% or smaller to prevent the substrate
from being roughened. From this point of view, the
smaller the elongation under the load of 9.8 N/cm, the
better, but an elongation of 100% or greater under the
load of 9.8 N/cm is required for ensuring comfort at
the time when wearing and taking off the fabric. It
has been found that if the ratio of the elongation is
0.80 or less, elongation in the weft direction is

greater than elongation in the warp direction, and if
the balance of the elongation is 1.200 or greater,
elongation in the warp direction is greater than
elongation in the weft direction, thus making it
difficult to obtain a comfort wearing feeling.
Preferably, the knitted fabric in which the
binding yarn 6 is bound to both ground knitted fabrics
at tuck weaves is excellent in stability, which is free
from a curling phenomenon such that the ear part is
curled up when being cut. Further, in the conventional
knitted fabric, the power can be different only for
warp and weft directions, but by knitting a fabric with
the tuck weave of the present invention, power-up in
the course direction alone is made possible, and the
warp/weft ratio of the elongation and power can be in a
range of 0.8 to 1.2.
The polyurethane based elastic fibers for use
in the present invention include not only polyurethane
elastic fibers but also polyether ester based elastic
fibers. For the polyurethane elastic fibers, for
example, dry-spun fibers or melt-spun fibers can be
used, and polymers and spinning processes are not
specifically limited. The size of fibers is usually 17
to 3000 decitexes, preferably 22 to 620 decitexes. The
break elongation is preferably 400% to 1200% for
obtaining fibers excellent in stretchability. Further,
it is preferable that stretchability is not compromised
at around 180°C which is a normal processing temperature

in a preset step during dyeing.
The polyurethane elastic fibers include, for
example, but not limited to, polyurethane elastic
fibers comprised of a copolymerized polyalkylene ether
diol, an aromatic diisocyanate mainly composed of 4,4-
diphenylmethane diisocyanate, and a polyurethane
obtained from bifunctional diamine, in which the number
average molecular weight of the urethane part of the
polyurethane is 6000 to 9500, the number average
molecular weight of the urea part is 650 to 950, the
300% modulus is 0.20 g/decitexes or less.
The non-elastic yarn constituting the front
and back ground knitted fabrics of the three-
dimensional knitted fabric of the present invention may
be any of a filament yarn and a spun yarn.
Specifically, filament yarns include preferably yarns
composed of synthetic fibers such as viscose rayon,
cupra rayon, acetate fibers, polyamide fibers,
polyester fibers, polytrimethylene terephthalate
fibers, acryl fibers, polypropylene fibers and vinyl
chloride fibers. The form of these fibers may be any
of a unprocessed gray yarn, a false twist finished
yarn, a colored yarn and the like, or may be a
composite yarn thereof. Spun yarns include preferably
yarns using short fibers composed of natural fibers
such as cotton, wool and hemp, and synthetic fibers
such as viscose rayon, cupra rayon, acetate fibers,
polyamide fibers, polyester fibers, acryl fibers,

polypropylene fibers and vinyl chloride fibers, and may
be single yarn or mixed yarn.
The gross size of a yarn that is used for
forming front and back ground knitted fabrics is
preferably in a range of 22 to 1220 decitexes, more
preferably 33 to 310 decitexes. The size of a single
yarn is preferably in a range of 0.1 to 310 decitexes,
more preferably 0.2 to 20 decitexes.
The elastic knitted fabric having a
multilayer structure, of the present invention, is
characterized in that the elastic knitted fabric is
easily subjected to heat molding. The multilayer
structure elastic knitted fabric of the present
invention having recessed portions and/or raised
portions formed and fixed by heat molding preferably
contains elastic fibers in the front or back ground
knitted fabric, more preferably in both the front and
back ground knitted fabrics. The mixing ratio of
polyurethane elastic fibers in the knitted fabric is
not limited, but is preferably 5 to 60% by mass. The
knitted fabric containing elastic fibers on the front
or back face is characterized in that mold
processability is improved, stretchability can be added
after molding, and the original shape is easily
recovered even if the knitted fabric is deformed under
an external pressure. The elastic fibers are
preferably polyurethane elastic fibers, and may be
identical to or different from polyurethane elastic

fibers used for the binding yarn. In this way, the
elastic knitted fabric having a multilayer structure,
of the present invention, has the skeletal structure of
the elastic knitted fabric formed by polyurethane based
elastic fibers, and is therefore easily subjected to
irregularity imposition processing due to the heat
fixation performance of polyurethane based elastic
fibers, and an irregular form after imposition
processing persists. This characteristic is
particularly remarkable in the elastic knitted fabric
with a three-dimensional structure having an air gap
between front and back two ground knitted fabrics, and
the elastic knitted fabric with a three-dimensional
structure is excellent in irregularity-retaining
properties owing to its rigidity. Of course, the non-
elastic yarn constituting the ground knitted fabric is
preferably composed of polyester fibers excellent in
thermoplasticity, polypropylene fibers having a
relative low melting point, or the like. The front and
back knitted fabrics may be separately formed with
these elastic yarns having different thermal
characteristics. For example, a knitted fabric with
the back face cured like a resin and the front face
having a soft feel giving comfort to the human skin is
obtained depending on the temperature and time during
imposition-type processing.
The gray fabric of the multilayer structure
elastic knitted fabric is capable of being opened,

subjected to preprocessing, then undergoing a dyeing
step and undergoing a finish set including resin
processing.
The multilayer structure elastic knitted
fabric of the present invention is characterized in
that a recessed portion or raised portion is formed and
fixed by heat molding. The method for carrying out
heat molding is not limited. If an overheating plate
is used, an elastic knitted fabric excellent in form
fixation characteristics and excellent in
recoverability for recovering the original shape even
if the knitted fabric is recessed under an external
force can be obtained.
As heat molding using an overheating plate,
for example, the front face is placed on a desired
concave female mold, and then pressed with a convex
male mold from the back face, and both layer parts are
heat-molded with the female mold previously heated to a
high temperature and the male mold previously heated to
a lower temperature than the female mold. It is
preferable that the space between the female mold and
the male mold is separated into required form-fixed
thicknesses, and heat press molding is carried out.
The heat molding temperature, the heat molding time,
the heat molding interval and the like may be selected
as appropriate according to a desired form.
The three-dimensional structure fabric of the
present invention has a volume retaining factor of

preferably 0.5 or greater, more preferably 0.6 or
greater. Where the mold volume of a mold for heat
molding is A, and the mold volume of a heat-molded
three-dimensional structure knitted fabric is B, the
volume retaining factor is calculated as B/A. If the
volume retaining factor of the heat mold form is less
than 0.5, the form of the knitted fabric is not
sufficiently retained after molding. For obtaining a
mold product using such a three-dimensional knitted
fabric, the elongation of the knitted fabric during
heat molding should be increased, and therefore the
step performance tends to be compromised such that yarn
breaking easily occurs.
For example, a specimen of 30 cm (warp) x 30
cm (weft) of the three-dimensional structure knitted
fabric is taken and subjected to helmet-shaped
male/female molding toward the center, whereby a helmet
cushion material capable of being used as a core
material of the helmet in a molded state and having a
three-dimensional structure is obtained. Furthermore,
a specimen of 20 cm (warp) x 45 cm (weft) is taken and
subjected to brassiere cup molding, and periphery is
sewn by an over lock sewing machine leaving only a
required part, whereby a sport brassiere can be
obtained.
The three-dimensional structure knitted
fabric of the present invention has independent front
and back knitted fabrics, and therefore a desired

knitted fabric can be obtained by changing a
combination of materials used for the front and back
knitted fabrics. If the front and back knitted fabrics
are tuck-knitted using a connecting yarn composed of
polyurethane elastic fibers, the knitted fabric, when
used for a supporter, etc., may preferably alleviate
the impact of an external force applied. The
multilayer structure elastic knitted fabric of the
present invention can be heat-molded into one part of a
desired three-dimensional structure, and then bound to
a different material (e.g. weave, knitted fabric,
leather, vinyl chloride sheet, etc.) by sewing to be
formed into a desired shape for use. Furthermore, it
can be subjected to flocky processing to raise one or
both faces for use.
In the elastic knitted fabric having a
multilayer structure, of the present invention, a
textile design can be given to the ground knitted
fabric by jacquard knitting using a plurality of non-
elastic yarns for the ground knitted fabric. Further,
in the elastic circular knitted fabric and the elastic
warp knitted fabric having a three-dimensional
structure, of the present invention, front and back two
ground knitted fabrics are partly bound in a contact
state, whereby a three-dimensional site and a linear or
planar three-layer structure site are formed and as a
result, a three-dimensional design having
irregularities can be given to the entire knitted

fabric.
For giving a three-dimensional design to the
surface of the ground knitted fabric, the feed amount
of connecting yarn may be reduced at any site to
substantially contact-bind front and back two ground
knitted fabrics, or change the distance between the two
ground knitted fabrics (thickness). Further, the non-
elastic yarn for forming one ground knitted fabric may
be used to form the other knitted fabric.
Further, the elastic knitted fabric of the
present invention is such that the elastic circular
knitted fabric having a three-dimensional structure,
the elastic circular knitted fabric having a three-
layer structure, and the three-dimensional site and the
linear or planar three-layer structure site with the
above elastic circular knitted fabrics combined are
formed. As a result, a three-dimensional design having
irregularities is given to the entire elastic knitted
fabric of the present invention, which may be applied
to a seamless formed cloth partly unopened and partly
sewn in a cylindrical form. The present invention can
implement a function required for each site of a cloth.
That is, taking shorts for cycling as an example, a
site corresponding to the saddle is three-dimensionally
knitted, and a three-layer structure elastic circular
knitted fabric of relatively high power is formed for a
site around the waist.
The present invention also relates to a

process for knitting a knitted fabric containing an
elastic yarn, and particularly to a process for
knitting an elastic circular knitted fabric
characterized in that when at least two elastic yarn
packages are fed from one yarn feeder in a circular
knitting machine, bare strings of elastic yarn are fed
at two or more different feed speeds.
Furthermore, the present inventors have found
a process for manufacturing an elastic knitted fabric
having a multilayer structure, characterized in that a
feed speed (V-g) of a bare string of polyurethane based
fibers knitting a ground knitted fabric is unequal to a
feed speed (V-c) of a bare string of polyurethane based
elastic fibers binding front and back knitted fabrics,
and made an apparatus for implementing the process. In
the active delivery process of delivering polyurethane
based elastic fibers to knitting needles from a spool
for bare strings of polyurethane based elastic fibers,
mounted on one circular knitting machine, the strings
are delivered at two or more different feed speeds,
whereby a various knitted fabrics , especially elastic
circular knitted fabrics having multilayer structures,
which have not been achievable, can be obtained.
Further, the present inventors have found
that by feeding the bare string of polyurethane based
elastic fibers binding front and back ground knitted
fabrics at a controlled draw ratio of 2 or less, a
three-layer structure knitted fabric with front and

back two ground knitted fabrics bound together as well
as a three-dimensional structure elastic circular
knitted fabric having an air gap between both the
ground knitted fabrics can be manufactured.
The present inventors devised an apparatus
for delivering a bare string of polyurethane based
elastic fibers required for manufacturing the
multilayer elastic circular knitted fabric of the
present invention. Traditionally, the feeder proposed
in JP-B-4-9222 has a pair of support rolls extending to
the left and right of the main body (holder), is driven
by a toothed tape associated with a knitting machine,
and can freely rotate a plurality of elastic yarn
packages on a pair of support-drive rolls attached to
the holder.
In the apparatus, however, if there is only
one toothed tape associated with the knitting machine,
the feed amount of polyurethane based elastic fibers is
all fixed. Thus, the present inventors devised a
method for changing the feed amount of polyurethane
based elastic fibers by increasing the number of
toothed tapes. In this case, however, four packages of
polyurethane based elastic fibers are placed in one
feeder, thus raising a problem such that the feed
amount is changed on a unit of four packages and thus
the degree of freedom is limited. Thus, the inventors
devised an apparatus capable of stably feeding strings
at different rates from elastic fiber packages with one

yarn feeder even if driven by one toothed tape.
Specifically, it is a yarn feeder characterized in that
a pair of cheese support-drive rollers extending in
parallel to each other, rotatably supported on a
holder, is so situated as to protrude in opposite
directions from the holder, driving means for rotating
the cheese support-drive roller is installed, and a
pair of cheese support-drive rollers having different
outer diameters is installed, and/or means for driving
in variable speed a pair of cheese support-drive
rollers in opposite directions is installed, so that
the surface speeds of the cheese support-drive rollers
are different for the opposite directions of the
holder. The pair of cheese support-drive rollers has a
through-hole in a cylinder core and has a part for
fixation so that it is detachably fixed to a drive
shaft. The yarn feeder is characterized by further
comprising another pre-drawing roller rotating at a
surface speed greater than that of the pair of cheese
support-drive rollers rotating at the same surface
speed.
The present invention proposes a method and
an apparatus for feeding an elastic yarn for knitting
an elastic knitted fabric in which two types should be
fed at different speeds. Typical examples of
conventional knitted fabrics made by cross-knitting
elastic bare strings include plain-knitted fabric, but
the knitted fabric is made by plain knitting the

elastic yarn arranged with the non-elastic yarn.
Furthermore, another example is a rib-knitted fabric
but in this case, the elastic yarn forms a plain-
knitted fabric with a dial needle. They each have one
type of elastic yarn weave, and can be treated by a
normal knitting machine with a single elastic yarn
feeder without any problems. The present inventors
invented an apparatus and method capable of feeding at
different speeds along with the invention of a new
weave requiring yarn feeding at different speeds.
That is, the elastic yarn feeder of the
present invention is mainly mounted concentrically
around a circular knitting machine, and can feed a bare
string of elastic fibers wound in a cheese form to the
knitting machine at a fixed speed while releasing and
draw-controlling the string.
The outline of the apparatus will be
described specifically below with reference to FIG. 4.
Furthermore, FIG. 5 is a sectional view of
the interior of a holder 15 of a yarn feeder of the
present invention seen from the side, and FIG. 6 is a
front view of the yarn feeder of the present invention.
In the yarn feeder, a pair of package
support-drive rollers (11-a and 11-b) extending in
parallel to each other, rotatably supported on the
holder (15) is so situated as to protrude in opposite
directions from the holder (15), and a toothed belt
(13) and a drive transmitting apparatus are installed

as driving means for rotating the package support-drive
roller. A pair of package support-drive rollers (11-a)
and (11-b) have different outer diameters so that the
surface speeds of the cheese support-drive rollers are
different for the opposite directions of the holder.
The pair of support-drive rollers has a structure such
that a through-hole is provided in a cylinder core, so
that the support roller can be fixed to a drive shaft,
and a change can be made as appropriate for a different
yarn speed ratio. Further, pre-draw rollers (12-a) and
(12-b) rotating at a surface speed greater than that of
the pair of package support-drive roller (11-a) or (11-
b) are provided, and a yarn breakage sensor (14) is
provided at a position between the package support-
drive roller (11-a) and the pre-draw roller (12-a) at
which the elastic yarn is draw-controlled after being
released. The diameter of the package support-drive
roller is 1 to 10 cm, and the ratio of the rotation
speed of a high yarn speed roller to the rotation speed
of a low yarn speed roller can be 10. Furthermore, the
pre-draw roller (12-a) or (12-b) rotates at a surface
speed greater by a factor of 1.2 to 2.0 than at least
the corresponding cheese support-drive roller (11-a) or
(11-b). Furthermore, reference symbols 10-a and 10-b
each denote a package with a bare string of
polyurethane based elastic yarn wound around a paper
tube.
An effect of the present invention is

described below: If an elastic feeder that has been
generally used as shown in JP-B-4-9222 is used, a cost
for additionally introducing a drive system and an
apparatus installation space are required for feeding
elastic yarns at different speeds as in conditions for
knitting the multilayer structure knitted fabric of the
present invention because the yarn speed is fixed.
Furthermore, the elastic yarn is slightly adhesive, and
thus often causes problems of release failure for high-
speed releasing and low draft releasing. The present
apparatus can solve the former problem at a low cost,
and can solve the latter problem by installing a pre-
draw roller.
The present invention will be specifically
described below with Examples.
Physical properties for use in the present
invention are measured as follows.
(1) Mass per unit area
Measurements are made according to the test
method of mass per square meter in JIS-L-1018.
(2) Thickness
KES-EB3 Compression Tester manufactured by
Kato Tech Co., Ltd. is used. A sample is held between
cupper plates each having a circular surface having an
area of 2 cm2 (compression speed 0.02 mm/sec), the
thickness of the sample is measured at five points
under a compressive pressure Pm of 0.5 g/cm2, and the
average of the measured values is calculated.

(3) Compressibility and Recovery rate
Measurements are made according to JIS-L-
1018. A three-dimensional knitted fabric is slit into
a size of 2 cm x 2 cm, one piece of slit fabric is
'placed on a measurement table, and a thickness A is
measured when an initial load of 20 cN is applied to an
area of 4 cm2 along the thickness from above. Then, a
load of 300 cN is applied to the area of 4 cm2, a
thickness B is measured after one minute, then the load
is removed and the sample is left standing for one
minute, and a thickness C is measured when the initial
load is applied again. The measurement is repeated
three times, a compressibility and a recovery rate are
calculated according to the following equations, and
the averages of the calculated values are determined.
Compressibility (%) = {(A-B)/A} x 100
Recovery rate (%) = {(C-B)/(A-B)} x 100
(4) Air permeability
KES-F8-AP1 Air Permeability Tester
manufactured by Kato Tech Co., Ltd. is used to measure
an air flow resistance five times, and the average of
the measured values is calculated.
(5) Feel of substrate
A determination is made based on the results
of sensory test by five monitors.
(6) Elongation and Elongation recovery rate
A knitted fabric is slit into a size of 2.5
cm x 15 cm. An elongation recovery curve of elongation


and recovery of the fabric is made under up to a
maximum load of 9.8 N/cm with a holding length of 10 cm
and at an elongation speed of 100 %/minute using a
constant speed elongation tester (Tensilon manufactured
by Toyo Baldwin Co, Ltd.). An elongation under the
load of 9.8 N/cm is read from this curve. Furthermore,
elongation ratios are determined from the following
equations.
Elongation ratio (A) = elongation (%) in warp
direction under load of 3.5 N/cm -s- elongation (%) in
weft direction
Elongation ratio (B) = elongation (%) in warp
direction under load of 9.8 N/cm + elongation (%) in
weft direction
The elongation recovery rate is determined,
according to the following equation, from an elongation
amount (c) under the load of 9.8 N/cm and an elongation
amount (d) when the load under recovery equals 0.
Elongation recovery rate (%) = (c-d) x 100/c
(7) Elastic fiber draw resistance
A knitted fabric is cut into a size having a
length of 7.5 cm and a width of 2.5 cm with the warp
direction as the direction of elastic fibers. Then,
both sides of one elastic fiber at the center in the
width direction is cut up to 1/3 in the warp direction,
and the elastic fiber is taken out from the knitted
fabric. Then, the elastic fiber is cut with scissors
at a position of 2.5 cm in the substrate of the elastic

fiber to fabricate a measurement specimen, and
measurements are made under the following measurement
conditions.
(Measurement conditions) The knitted fabric
portion and the elastic fiber are each held by the
constant speed elongation tester (Tensilon manufactured
by Toyo Baldwin Co., Ltd.), and the elastic fiber is
drawn at an elongation speed of 30 cm/minute. The
resistance at this time is recorded, and the average of
draw stress peaks is determined.
(8) Volume retaining factor
For the molding volume of a knitted fabric, a
thermoplastic film (synthetic resin film softened with
dry heat of 80 to 100°C) is placed on the surface of a
molded knitted fabric, the same mold shape is retained
along a recessed or raised portion of the knitted
fabric with dry heat air (a dryer set at a softening
temperature), and then the thermoplastic film is fixed
with cool air. Water is made to flow over the
thermoplastic film retaining the shape of the recessed
and raised portions of the knitted fabric to measure
the volume.
The volume of a mold used for molding is a
heat molding volume. The volume of the molded knitted
fabric is measured, and the volume retaining factor is
calculated according to the following equations.
Volume retaining factor = (molding volume
retained by molded knitted fabric)/ (heat molding

volume)
Example 1
A polyester false twist finished yarn of 84
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) was used as a yarn for use in
a front knitted fabric and a back knitted fabric of a
three-dimensional knitted fabric to form a knitted
fabric into plain stitch. A bare string of
polyurethane based elastic fibers of 155 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used as a yarn for binding the front and back knitted
fabrics together.
Bind-knitting was performed with all the
needles of an interlock double circular knitting
machine of 28 gage, 30 inch diameter and 60 aperture
(Model Type V-LEC6 manufactured by Fukuhara Works,
Ltd.) to obtain a circular knitted fabric with the
distance between unit patterns set to 4 mm. At this
time, the loop length of the bare string of
polyurethane based elastic fibers was 800 cm, and the
loop length of the knitted fabric constituting the
front face and the back face was 827 cm, resulting in
the loop length ratio (T) of 1.0.
The obtained circular knitted grey fabric was
opened, refined by a jet dyeing machine at 80°C for 30
minutes, and heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset. Then, the fabric was dyed at

130°C for 60 minutes using a high pressure jet dyeing
machine. The fabric was heat-treated at 170°C for 45
seconds while tentering by 3% in the width direction
using a tenter finisher as a finishing set to obtain a
dyed fabric. Knitting specifications and knitting
characteristics in this case are shown in Tables 1 and
2.
The obtained three-dimensional knitted fabric
had a thickness of 2.65 mm, a compressibility of 60%, a
recovery ratio of 92.0% and an air permeability of
0.45, and had a good feel. This three-dimensional
knitted fabric was very suitable for inner sole
materials of shoes and the like, bed pats of life
materials and the like.
Example 2
A front knitted fabric and a back knitted
fabric of a three-dimensional knitted fabric were
knitted in the same manner as in Example 1. A bare
string of polyurethane based elastic fibers of 310
decitexes (Roica® manufactured by Asahi Kasei
Corporation) was used as a yarn for binding the front
and back knitted fabrics together. At this time, bind-
knitting was performed with all needles. The obtained
knitted fabric was subjected to processing same as that
of Example 1. Knitting specifications and knitting
characteristics in this case are shown in Tables 1 and
2.
The obtained three-dimensional knitted fabric

had a thickness of 3.12 mm, a compressibility of 55%, a
recovery ratio of 99.4% and an air permeability of
0.41, and had a good feel. This three-dimensional
knitted fabric was very suitable for inner sole
materials of shoes and the like, bed pats of life
materials and the like.
Example 3
Knitting was performed in the same manner as
in Example 2 except that binding was performed with 1/2
of needles as bind-knitting conditions. Knitting
specifications and knitting characteristics in this
case are shown in Tables 1 and 2.
The obtained three-dimensional knitted fabric
had a thickness of 3.00 mm, a compressibility of 60%, a
recovery ratio of 97.4% and an air permeability of
0.55, and had a good feel. This three-dimensional
knitted fabric was very suitable for inner sole
materials of shoes and the like, bed pats of life
materials and the like.
Example 4
Knitting was performed in the same manner as
in Example 2 except that binding was performed with 1/4
of needles as bind-knitting conditions. Knitting
specifications and knitting characteristics in this
case are shown in Tables 1 and 2. The obtained three-
dimensional knitted fabric had a thickness of 2.85 mm,
a compressibility of 71%, a recovery ratio of 91.6% and
an air permeability of 0.62, and had a good feel. This

three-dimensional knitted fabric was very suitable for
inner sole materials of shoes and the like, bed pats of
life materials and the like.
Example 5
A cotton spun yarn No. 40 was used as a yarn
for use in a front knitted fabric of a three-
dimensional knitted fabric, and a polyester memory
twist finished yarn of 167 decitexes and 48 filaments
(Technofine® manufactured by Asahi Kasei Corporation)
was used as a yarn for use in a back face to form
knitted fabrics of both faces into plain stitch. A
bare string of polyurethane based elastic fibers of 310
decitexes (Roica® manufactured by Asahi Kasei
Corporation) was used as a yarn for binding the front
and back knitted fabrics together to perform bind-
knitting with all needles.
An interlock double circular knitting machine
of 22 gage, 30 inch diameter and 36 aperture (Model
Type OVJ-36 manufactured by Mayer Cie Co., Ltd.) was
used to knit a circular knitted fabric with the
distance between unit patterns set to 5 mm. At this
time, the loop length of the bare string of
polyurethane based elastic fibers was 2160 cm, and the
loop length of the knitted fabric constituting the
front face and the back face was 1063 cm, resulting in
the loop length ratio (T) of 2.0. This circular
knitted fabric was subjected to finish processing same
as that of Example 1 to obtain a three-dimensional

knitted fabric of the present invention. Knitting
specifications and knitting characteristics in this
case are shown in Tables 1 and 2.
The obtained three-dimensional knitted fabric
had a thickness of 3.35 mm, a compressibility of 65%, a
recovery ratio of 99.0% and an air permeability of
1.18, and had a good feel. This three-dimensional
knitted fabric was very suitable for inner sole
materials of shoes and the like, bed pats of life
materials and the like.
Example 6
A front knitted fabric and a back knitted
fabric of a three-dimensional knitted fabric were
knitted in the same manner as in Example 5. A bare
string of polyurethane based elastic fibers of 34
decitexes (Roica® manufactured by Asahi Kasei
Corporation) was used as a yarn for binding the front
and back knitted fabrics together. The obtained
circular knitted fabric was subjected to processing
same as that of Example 5. Knitting specifications and
knitting characteristics in this case are shown in
Tables 1 and 2.
The obtained three-dimensional knitted fabric
had a thickness of 2.23 mm, a compressibility of 72%, a
recovery ratio of 86.2% and an air permeability of
0.45, and had a good feel. This three-dimensional
knitted fabric was very suitable for inner sole
materials of shoes and the like, bed pats of life

materials and the like.
Comparative Example 1
A front knitted fabric and a back knitted
fabric of a three-dimensional knitted fabric were
knitted in the same manner as in Example 1. A bare
string of polyurethane based elastic fibers of 155
decitexes (Roica® manufactured by Asahi Kasei
Corporation) and a polyester core sheathing type heat
seal yarn of 83 decitexes and 24 filaments (Bell
Couple® manufactured by Kanebo Gohsen, Ltd.) were used
as yarns for binding the front and back knitted fabrics
together. The elastic fibers were arranged with the
heat seal yarn multifilament and subjected to
confounding processing while the fibers were elongated
by a factor of 2.5, and then they were twisted in the
twist direction Z at a set number of twists of 600
times/m using the following twisting machine to
fabricate a piled yarn.
Interlacer (PC-220 Type
manufactured by Toray Precision Co., Ltd.) pneumatic
pressure; 2.0 KG/Cm G
Yarn twisting machine; Itarly Yarn Twisting
Machine (TKT Type manufactured by Kubota Co., Ltd.)
The obtained twisted yarn was used to bind
front and back knitted fabrics together with all
needles to knit a circular knitted fabric, the obtained
circular knitted fabric was subjected to processing
same as that of Example 1. Knitting specifications and

knitting characteristics in this case are shown in
Tables 1 and 2.
The obtained circular knitted fabric had a
thickness of 1.87 mm, a compressibility of 5%, a
recovery rate of 82.0% and an air permeability of 1.33.
This three-dimensional knitted fabric was poor in
compressibility, hard with lack of stereoscopic vision
in terms of a feel and the like, and unsuitable for bed
pats of life materials and the like.
Comparative Example 2
A front knitted fabric and a back knitted
fabric of a three-dimensional knitted fabric were
knitted in the same manner as in Example 5. The three-
dimensional knitted fabric was knitted just in the same
manner as in Example 5 except that a bare string of
polyurethane based elastic fibers of 15 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used as a yarn for binding the front and back knitted
fabrics together. Knitting specifications and knitting
characteristics in this case are shown in Tables 1 and
2.
The obtained circular knitted fabric had a
thickness of 1.95 mm, a compressibility of 80%, a
recovery rate of 45% and an air permeability of 0.23,
had a soft feel, and was unsuitable for bet pads of
life materials and the like in terms of compression
recoverability, a feel and the like.
Example 7

An interlock double circular knitting machine
of 28 gage, 30 inch diameter and 60 aperture (Model
Type V-LEC6 manufactured by Fukuhara Works, Ltd.) was
used to knit a stretchable circular knitted fabric
having a three-layer structure. The distance between
unit patterns of the knitting machine was set to 1 mm.
A polyester false twist finished yarn of 56
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) and a bare string of
polyurethane based elastic fibers of 22 decitexes
(Roica® manufactured by Asahi Kasei Corporation) were
used as yarns for use in a front knitted fabric and a
back knitted fabric of the elastic circular knitted
fabric to form a knitted fabric into plain stitch
(generally called bare weaves), and a bare string of
polyurethane based elastic fibers of 155 decitexes
(Roica) was used as a yarn for binding the front and
back knitted fabrics together to tuck-connect the front
and back knitted fabrics with 1/2 of a total number of
needles with one needle for front and back knitted
fabrics alternately.
At this time, the loop length of the bare
string of polyurethane based elastic fibers as a
binding yarn, equivalent to one round of the knitting
machine, was 190 cm (A), the loop length of the
polyester false twist finished yarn constituting one
face and the other face was 850 cm (B), and the loop
length ratio of the binding yarn (A/B) was 0.22.

The obtained circular knitted grey fabric was
opened, refined by a jet dyeing machine at 80°C for 30
minutes, and heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset. Then, the fabric was dyed at
130°C for 60 minutes using a high pressure jet dyeing
machine. The fabric was heat-treated at 170°C for 45
seconds while tentering by 3% in the width direction
using a tenter finisher as a finishing set to obtain a
dyed fabric. Knitting specifications and knitting
characteristics in this case are shown in Tables 3 and
4.
The obtained elastic circular knitted fabric
had a three-layer structure with front and back ground
knitted fabrics bound together, had a thickness of 0.58
mm, an elongation of 130% in the longitudinal direction
and 158% in the lateral direction, elongation recovery
rate of 91% in the longitudinal direction and 93% in
the lateral direction, and an elastic fiber draw stress
of 80 g, and had a good feel.
This elastic circular knitted fabric was free
from a run from the end of the knitted fabric, required
no sewing on the end surface, and was excellent in fit
feeling and shape complementing functions as girdles
for ladies.
Example 8
Knitting was performed under the same
conditions as those in Example 7 except that a bare

string of polyurethane based elastic fibers of 44
decitexes (Roica) was used as a yarn for binding front
and back knitted fabrics of an elastic circular knitted
fabric to perform bind-knitting with all needles, and
same processing as that of Example 7 was carried out to
obtain a three-dimensional structure elastic circular
knitted fabric.
The obtained elastic circular knitted fabric
had a thickness of 0.55 mm, an elongation of 133% in
the longitudinal direction and 181% in the lateral
direction, elongation recovery rate of 92% in the
longitudinal direction and 93% in the lateral
direction, and an elastic fiber draw stress of 50 g or
greater, and had a good feel.
This elastic circular knitted fabric was free
from a run from the end of the knitted fabric, required
no sewing on the end surface, and was excellent in fit
feeling and shape complementing functions as girdles
for ladies.
Example 9
An elastic circular knitted fabric was
obtained just in the same manner as in Example 8 except
that front and back ground knitted fabrics were bound
together with 1/2 of needles as bind-knitting
conditions. The obtained three-layer structure elastic
circular knitted fabric had a thickness of 0.55 mm, an
elongation of 135% in the longitudinal direction and
183% in the lateral direction, elongation recovery rate

A circular knitting machine of 18 gage, 30
inch diameter and 36 aperture (Mbdel Type OVJ-36
manufactured by Mayer Cie Co., Ltd.) was used to knit a
circular knitted fabric.
As yarns for use in a front knitted fabric of
the elastic circular knitted fabric, a cotton spun yarn
No. 40 and a polyurethane elastic yarn of 22 decitexes
(Roica® manufactured by Asahi Kas'ei Corporation) were
used for the core, and an elastic yarn covered with a
nylon finished yarn of 34 decitexes/12 filaments was
arranged. A polyester false twist finished yarn of 167
decitexes and 48 filaments (Technofine) was used as a
yarn for use in the back knitted fabric, the knitted
fabric of each face was formed into plain stitch, a
bare string of polyurethane based elastic fibers of
1422 decitexes (Roica) was used as a binding yarn for
binding the front and back knitted fabrics, and tuck-
knitting was performed with 1/2 of a total number of
needles.
At this time, the loop length of the bare
string of polyurethane based elastic fibers was 190 cm,
the loop lengths of knitted fabrics constituting one
face and the other face were both 950 cm, and the loop
length ratio was 0.20.
The obtained stretchable knitted fabric had a
thickness of 0.78 mm, an elongation of 80% in the
longitudinal direction and 100% in the lateral
direction, elongation recovery rate of 92% in the

longitudinal direction and 93% in the lateral
direction, and an elastic fiber draw stress of 80 g or
greater, and had a good feel, but suffered curling of
the knitted fabric.
This stretchable knitted fabric had a run
occurring from the end of the knitted fabric, and
therefore the end faces were sewn. The knitted fabric
had good handling characteristics during sewing
operations, and was excellent in fit feeling and shape
complementing functions as girdles for ladies.
Example 12
The knitting machine of Example 11 was
changed to a rib gatting, first and third yarn feeding
ports were set to dial plain stitch and cylinder 1/2
needle tuck weaves, second and fourth yarn feeding
ports were set to cylinder plain stitch and dial 1/2
needle tuck weaves, and when a cotton spun yarn No. 40
was used as a yarn for use in a front face on the
cylinder side, and a polyester false twist finished
yarn of 167 decitexes and 48 filaments (Technofine) was
used as a yarn for use in a back face at the dial side
to knit a plain stitch part, combined yarn feeding was
performed allowing tuck knitting alternately in
relative needle rows while knitting a plain stitch part
at each yarn feeding port using a bare string of
polyurethane based elastic fibers of 34 decitexes
(Roica) as a yarn for binding front and back knitted
fabrics together. That is, the connecting yarn was for

elastic yarn connection with the knit for one side and
the tuck for the corresponding side. For other
aspects, operations were carried out in the same manner
as in Example 5 to obtain a stretchable knitted fabric.
The obtained stretchable knitted fabric had a
thickness of 0.74 mm, an elongation of 80% in the
longitudinal direction and 130% in the lateral
direction, elongation recovery rate of 93% in the
longitudinal direction and 92% in the lateral
direction, and an elastic fiber draw stress of 50 g or
greater, and had a good feel.
This stretchable knitted fabric had a run
occurring from the end of the knitted fabric, and
therefore the end faces were sewn. The knitted fabric
had good handling characteristics during sewing
operations, and was excellent in fit feeling and shape
complementing functions as girdles for ladies.
Comparative Example 3
A circular knitting machine of 18 gage, 30
inch diameter and 36 aperture (Model Type OVJ-36
manufactured by Mayer Cie Co., Ltd.) was used to knit a
circular knitted fabric.
A cotton spun yarn No. 40 was used as a yarn
for use in a front knitted fabric of the stretchable
knitted fabric, a polyester false twist finished yarn
of 167 decitexes and 48 filaments (Technofine) was used
as a yarn for use in a back knitted fabric, and when a
knitted fabric of half-bag weaves was knitted, a bare

string of polyurethane based elastic fibers of 1422
decitexes (Roica) was inflation-inserted at a yarn
feeding port of 1/2 to knit the fabric.
At this time, the loop length of the bare
string of polyurethane based elastic fibers was 190 cm,
the loop lengths of knitted fabrics constituting one
face and the other face were both 760 cm, and the loop
length ratio was 0.25.
The obtained stretchable knitted fabric had a
thickness of 0.80 mm, an elongation of 45% in the
longitudinal direction and 100% in the lateral
direction, elongation recovery rate of 60% in the
longitudinal direction and 75% in the lateral
direction, and a draw stress of 40 g. This stretchable
knitted fabric was poor in elongation, and had poor
handling characteristics with elastic fibers easily
falling off during sewing operations.
Comparative Example 4
A front knitted fabric and a back knitted
fabric of a stretchable knitted fabric were knitted in
the same manner as in Example 7. Using a bare string
of polyurethane based elastic fibers of 155 decitexes
(Roica) and a polyamide multifilament of 44 decitexes
and 34 filaments (Leona) as yarns for binding the front
and back knitted fabrics, the elastic fibers were
arranged with the polyamide multifilament and subjected
to confounding processing under the following condition
while the fibers were elongated by a factor of 2.5.

Then they were twisted in the twist direction Z at a
set number of twists of 600 times/m using the following
twisting machine to fabricate a piled yarn.
Interlacer (PC-220 Type
manufactured by Toray Precision Co., Ltd.) pneumatic
pressure; 2.0 KG/cm2G
Yarn twisting machine; Itarly Yarn Twisting
Machine (TKT Type manufactured by Kubota Co., Ltd.)
Using the obtained piled yarn as a yarn for
binding the front and back knitted fabrics, tuck-
knitting was performed with 1/2 of a number of bindings
to knit a circular knitted fabric.
The obtained stretchable knitted fabric had a
thickness of 0.60 mm, an elongation of 100% in the
longitudinal direction and 120% in the lateral
direction, elongation recovery rate of 75% in the
longitudinal direction and 60% in the lateral
direction, and an elastic fiber draw stress of 100 g,
and had an irregular outline.
This stretchable knitted fabric had a bad
appearance with a binding yarn protruding from the
surface, and was poor in stretchability and thus
unsuitable as girdles for ladies.
Comparative Example 5
A stretchable knitted fabric was obtained in
the same manner as in Example 5 except that a bare
string of polyurethane based elastic fibers of 11
decitexes (Roica) was used as a yarn for binding front

and back knitted fabrics, as in Example 12.
The obtained knitted fabric had a thickness
of 0.75 ram, an elongation of 40% in the longitudinal
direction and 87% in the lateral direction, and
elongation recovery rate of 89% in the longitudinal
direction and 75% in the lateral direction, and was
poor in stretchability.
Example 13
A polyester false twist finished yarn of 84
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) and a bare string of
polyurethane based elastic fibers of 22 decitexes
(Roica® manufactured by Asahi Kasei Corporation) were
used as yarns for use in a front knitted fabric and a
back knitted fabric of a three-dimensional knitted
fabric to arrange these two yarns to form a knitted
fabric into plain stitch. A bare string of
polyurethane based elastic fibers of 155 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used as connecting yarn for binding the front and back
knitted fabrics together.
An interlock double circular knitting machine
of 28 gage, 30 inch diameter and 60 aperture (Model
Type V-LEC6 manufactured by Fukuhara Works, Ltd.) was
used to perform knitting to obtain a circular knitted
fabric with the distance between unit patterns of the
knitting machine set to 4.0 mm.
The obtained circular knitted grey fabric was

opened, refined by a jet dyeing machine at 80°C for 30
minutes, and heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset. Then, the fabric was dyed at
130°C for 60 minutes using a high pressure jet dyeing
machine. The fabric was heat-treated at 170°C for 45
seconds while tentering by 3% in the width direction
using a tenter finisher as a finishing set to obtain a
dyed fabric. The obtained knitted fabric was heat-
molded for 45 seconds using a mold for heat molding of
volume 300 cm3 dry-heated to 190°C. Knitting
specifications and knitting characteristics in this
case are shown in Tables 5 and 6.
The obtained three-dimensional structure
knitted fabric had a mass per unit area of 350 g/m2, a
thickness of 2.2 mm, a post-heat molding substrate
volume of 210 cm3, and a volume retaining factor of 0.7.
This three-dimensional structure knitted fabric was
excellent in form fixation characteristics and
resilience for recovering an original shape after
recessed under an external force, and very suitable for
shoe materials, brassiere cup materials, swimming suits
and body suits to be molded before use, and shoulder
pats, corsets, hats and the like, having the form
fixedly retained, as well as outer edge materials and
inner edge materials for containers.
Example 14
As in the case of Example 13, a polyester

false twist finished yarn of 84 decitexes and 30
filaments (Technofine® manufactured by Asahi Kasei
Corporation) and a bare string of polyurethane based
elastic fibers of 22 decitexes ( (low-temperature high
set type yarn) Roica BX® manufactured by Asahi Kasei
Corporation) were used as yarns for use in a front
knitted fabric and a back knitted fabric of a three-
dimensional knitted fabric to arrange these two yarns
to form a knitted fabric into plain stitch. A bare
string of synthetic polyurethane based elastic fibers
of 155 decitexes (Roica® manufactured by Asahi Kasei
Corporation) was used as yarn for binding the front and
back knitted fabrics together.
The obtained knitted fabric was subjected to
processing same as that of Example 13.
The obtained three-dimensional structure
knitted fabric had a mass per unit area of 400 g/m2, a
thickness of 2.5 mm, a post-heat molding substrate
volume of 270 cm3, and a volume retaining factor of 0.9.
This three-dimensional structure knitted fabric was
excellent in form fixation characteristics and
resilience for recovering an original shape after
recessed under an external force, and very suitable for
shoe materials, brassiere cup materials, swimming suits
and body suits to be molded before use, and shoulder
pats, corsets, hats and the like, having the form
fixedly retained, as well as outer edge materials and
inner edge materials for containers.


Example 15
A polyester false twist finished yarn of 84
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) and a bare string of
polyurethane based elastic fibers of 22 decitexes
(Roica® manufactured by Asahi Kasei Corporation) were
used as yarns for use in a front knitted fabric and a
back knitted fabric of a three-dimensional knitted
fabric to arrange these two yarns to form a knitted
fabric into plain stitch. A bare string of
polyurethane based elastic fibers of 78 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used as a yarn for binding the front and back knitted
fabrics together. For other aspects, the knitted
fabric was knitted and processed in the same manner as
in Example 13.
The obtained three-dimensional structure
knitted fabric had a mass per unit area of 230 g/m2, a
thickness of 2.1 mm, a post-heat molding substrate
volume of 240 cm3, and a volume retaining factor of 0.8.
This three-dimensional structure knitted fabric was
excellent in form fixation characteristics and
resilience for recovering an original shape after
recessed under an external force, and very suitable for
shoe materials, brassiere cup materials, swimming suits
and body suits to be molded before use, and shoulder
pats, corsets, hats and the like, having the form
fixedly retained, as well as outer edge materials and

inner edge materials for containers.
Comparative Example 6
A polyester false twist finished yarn of 84
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) was used as a yarn for use in
front back knitted fabrics of a three-dimensional
knitted fabric to form a knitted fabric into plain
stitch. The polyester false twist finished yarn of 84
decitexes and 30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) was used as a yarn for binding
the front and back knitted fabrics together. For other
aspects, the knitted fabric was knitted and processed
in the same manner as in Example 13.
The obtained knitted fabric had a mass per
unit area of 250 g/m2, a thickness of 1.8 mm, a post-
heat molding substrate volume of 12 0 cm3, and a volume
retaining factor of 0.4, and was poor in form retaining
characteristics (deformed), and unsuitable for life
materials and the like.
Example 16
A polyurethane elastic yarn of 155 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used alone in a bare state as a connecting yarn for
binding front and back ground knitted fabrics of a
three-dimensional knitted fabric. For the back ground
knitted fabric, a polyester false twist finished yarn
of 84 decitexes/30 filaments (Technofine® manufactured
by Asahi Kasei Corporation) and a bare string of

polyurethane elastic yarn of 22 decitexes (Roica®
manufactured by Asahi Kasei Corporation) were arranged
to form a knitted fabric into plain stitch. For the
front ground knitted fabric, a false twist finished
yarn of nylon of 78 decitexes/34 filaments and the
polyurethane elastic yarn of 22 decitexes were arranged
to form a knitted fabric in the same manner as in the
formation of the back knitted fabric.
As a knitting machine, double circular
knitting machine of 28 gage, 30 inch diameter and 60
aperture (Model Type V-LEC6 manufactured by Fukuhara
Works, Ltd.) was used. The tooth space between a dial
needle and a cylinder needle of the knitting machine
was set to 4 mm. The non-elastic nylon false twist
finished yarn for forming the front ground knitted
fabric was fed from a yarn feeding port 1 to the
cylinder needle in a feeding length (loop length) of
827 cm per one rotation of the knitting machine, and
the non-elastic polyester false twist finished yarn for
forming the back ground knitted fabric was fed from a
yarn feeding port 2 to a dial needle in the same
feeding length (loop length) of 827 cm per one rotation
of the knitting machine.
An apparatus for actively delivering in a
bare state from a package the polyurethane elastic yarn
to be arranged with a main material forming the ground
knitted fabric was used. The yarn was fed from the
first yarn feeding port and the second yarn feeding

port of the knitting machine to knitting needles in a
feeding length of 410 cm per one rotation of the
knitting machine (draw ratio of polyurethane elastic
yarn during knitting was 2.0), and plain knitted to
form the front and back ground fabrics. The connecting
yarn was fed in double tuck weaves from a third yarn
feeding port to short butt needles for both dial and
cylinder needles in a feeding length of 800 cm per one
rotation of the knitting machine, and the ground
knitted fabrics formed at the first yarn feeding port
and the second yarn feeding port were bound in tuck
stitches. Operations at the first yarn feeding port
and the second yarn feeding port were repeated at a
fourth yarn feeding port and a fifth yarn feeding port,
respectively, and at a sixth yarn feeding port, the
polyurethane elastic yarn was fed to long butt needles
for dial and cylinder needles as in the case of the
third yarn feeding port.
With this yarn as one complete weave, a
fabric was knitted at 60 aperture yarn feeding port.
Since connecting yarn was knitted in double tuck weaves
with the short butt needle and the long butt needle
alternately for each course, the stitch rate of the
ground knitted fabric bound to the connecting yarn was
50%, and the connection site was shifted in phase for
each course.
The obtained circular knitted grey fabric was
opened, refined by a jet dyeing machine at 80°C for 30

minutes, heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset, and then dyed on the nylon side
with an acid dye at 100°C for 60 minutes using a high
pressure jet dyeing machine. The fabric was heat-
treated at 170°C for 45 seconds while tentering by 3% in
the width direction using a tenter finisher as a
finishing set to obtain a dyed fabric.
The obtained three-dimensional knitted fabric
had a thickness of 1.8 mm, a knitting density of 25.5
courses/cm x 14.6 wale/cm, a total connection number
per square cm of 373, connecting yarn total decitexes
per square cm of 57,780 decitexes, and D/T of 32,100.
This elastic knitted fabric had a compressibility of
54% and a recovery rate of 100%, and thus had
sufficient compressibility. The knitted fabric had an
air flow resistance of 0.24 kPa--s/m, and was
sufficiently stretchable in both warp and weft
directions of the knitted fabric, and completely
reversible for back and front faces.
Example 17
A polyurethane elastic yarn of 78 decitexes
(Roica® manufactured by Asahi Kasei Corporation) was
used alone in a bare state as polyurethane elastic
fibers for a connecting yarn for binding ground knitted
fabrics together, and a polyester gray yarn of 84
decitexes/30 filaments (Technofine® manufactured by
Asahi Kasei Corporation) and a polyurethane elastic

yarn of 22 decitexes (Roica® manufactured by Asahi
Kasei Corporation) were used in a bare state for front
and back ground knitted fabrics. As a knitting
machine, a double raschel warp knitting machine of 18
gage provided with five guide bars (manufactured by
Karl Mayer Co., Ltd.) with the distance between unit
patterns set to 4 mm was used. The polyester gray yarn
and the polyurethane elastic yarn for the ground
knitted fabrics were fed to only a front needle from a
first guide bar and a second guide bar to knit a double
lxl tricot stitch weave. Two types of yarns were
similarly fed to only a back needle from a fourth guide
bar and a fifth guide bar to knit a half weave. From a
third guide bar, a bare string of polyurethane elastic
yarn was fed as a connecting yarn to both the front
needle and back needle alternately in a full set, and a
knit loop was knitted and connected to the ground
knitted fabrics. The obtained warp knitted grey fabric
was refined by a continuous refining machine at 80°C for
30 minutes, heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset, and then dyed at 130°C for 60
minutes using a high pressure jet dyeing machine. The
fabric was heat-treated at 170°C for 45 seconds while
tentering by 3% in the width direction using a tenter
finisher as a finishing set to obtain a dyed fabric.
The obtained elastic knitted fabric had a
thickness of 2.5 mm, a knitting density of 23.6

courses/cm x 11.8 wale/cm, total connection number per
square cm of 558, connecting yarn total decitexes per
square cm of 43,524 decitexes, and D/T of 17,410.
This elastic knitted fabric had a
compressibility of 69% and a recovery rate of 99.4%,
and thus had sufficient compressibility. The knitted
fabric had a satisfactory air flow resistance of 0.33,
and was sufficiently stretchable in both warp and weft
directions of the knitted fabric. The obtained elastic
knitted fabric was molded under dry heat conditions at
180°C for 30 seconds using a rugged human face mold made
of aluminum, resulting in a knitted fabric most
suitable as an eye mask having a shape of a human face.
Example 18
A knitting machine same as that of Example 16
was used, no elastic yarn was used for a back ground
knitted fabric, and an elastic yarn having a
polyurethane elastic' yarn of 22 decitexes (Roica®
manufactured by Asahi Kasei Corporation) as a core
covered with a nylon finished yarn of 34 decitexes/12
filaments was used for a front ground knitted fabric.
In the same manner as in Example 16 for other aspects,
this elastic yarn was arranged with non-elastic fibers
at a rate of one of two of fibers to form a knitted
fabric into plain stitch.
The obtained elastic knitted fabric had a
thickness of 2.0 mm, a knitting density of 18
courses/cm x 11 wale/cm, total connecting yarn number

per cm of 198, and D/T of 17,050. This elastic knitted
fabric had a compressibility of 69% and a recovery rate
of 99.9%, and thus had sufficient compressibility. The
elastic knitted fabric was sufficiently stretchable in
both warp and weft directions of the knitted fabric,
and most suitable as upper materials for shoes and
boots.
Example 19
A double circular knitting machine of 22G
comprising a jacquard patterning mechanism with needle
selection was used, a false twist finished yarn of
nylon of 78 decitexes/34 filaments and a gray yarn of
polyester 84 of decitexes/30 filaments were fed to the
cylinder side to knit a flowered two-color jacquard and
at the same time, a polyurethane elastic yarn of 44
decitexes (Roica® manufactured by Asahi Kasei
Corporation) was plated in a bare state to form a front
ground knitted fabric.
A gray yarn of polyester of 84 decitexes/30
filaments was fed to the dial needle to knit a plain-
knitted fabric and at the same time, a polyurethane
elastic yarn of 44 decitexes (Roica® manufactured by
Asahi Kasei Corporation) was plated in a bare state to
form a back ground knitted fabric. The front and back
two ground knitted fabrics were bound together by
performing double tuck knitting alternately with a
short butt needle and a long butt needle using a
polyurethane elastic yarn of 310 decitexes (Roica®

manufactured by Asahi Kasei Corporation) as a
connecting yarn in the same manner as in Example 16.
The obtained circular knitted grey fabric was
opened, refined by a jet dyeing machine at 80°C for 30
minutes, heat-treated at 190°C for 60 seconds while
tentering by 5% in the width direction by a tenter
finisher as a preset, and then dyed on the nylon side
with an acid dye at 100°C for 60 minutes using a high
pressure jet dyeing machine. The fabric was heat-
treated at 170°C for 45 seconds while tentering by 3% in
the width direction using a tenter finisher as a
finishing set to obtain a dyed fabric.
The obtained knitted fabric had a thickness
of 5 mm, a density of 28 courses/cm x 15 wale/cm, a
connecting yarn total number of 420, and D/T of 26,040.
This elastic knitted fabric had a compressibility of
50% and a recovery rate of 100%, and thus had
sufficient compressibility. The knitted fabric was
sufficiently stretchable in both warp and weft
directions, and had white stitches knitted with
polyester on the surface, thus being most suitable for
warm swimming suits having flowered patterns.
Example 20
In knitting an elastic knitted fabric of the
present invention with similar yarn handling operations
by a double raschel warp knitting machine used in
Example 17, 80 course knitting was performed in the
same manner as in Example 17 and in next 10 courses, a

polyester gray yarn in a second guide bar was knitted
with both front and back needles to form a knit loop,
during which a connecting yarn was prevented from being
connected to ground knitted fabrics, and inserted
between two ground knitted fabrics in a float yarn
state.
Then, a return was made to the original
knitted weave to perform knitting of 80 courses, and
this operation was repeated. The obtained elastic
knitted fabric had border-type irregularities with a
three-dimensional site partitioned every 3 cm in the
warp direction of the knitted fabric. This elastic
knitted fabric had a recessed portion, and therefore
could be easily bent on the whole, thus being most
suitable for supporters and the like to be wound around
the human body.
Comparative Example 7
Using a knitting machine same as that of
Example 16, a knitted fabric was knitted with weaves
and conditions same as those of Example 16. At this
time, yarn handling for the ground knitted fabric was
carried out in the same manner as in Example 16, and a
false twist finished yarn of polyester of 167
decitexes/48 filaments was used as a binding yarn. The
obtained knitted fabric was dye-finished using steps
and conditions same as those of Example 16.
This knitted fabric had a thickness of 2.2
mm, a knitting density of 25.5 courses/cm x 14.6

wale/cm, total connection number per square cm of 373,
connecting yarn total decitexes per square cm of 62,291
decitexes, and D/T of 22,246.
This knitted fabric had a compressibility of
62%, a recovery rate of 68.8%, and an air flow
resistance of 0.64 kPa--s/m. The knitted fabric was
sufficiently stretchable in both warp and weft
directions of the knitted fabric, but was poor in
elasticity when compressed in the thickness direction,
and insufficient in compression recoverability such
that it took much time for recovery from compression
and permanent deformation remains on the surface of the
knitted fabric for a long time. Furthermore, the
knitted fabric was filled with fibers at the connection
part and inferior in air permeability to the elastic
fabric of the present invention. Further, this knitted
fabric was dyed in a rope state, and thus had rope
creases persistent on the surface of the knitted fabric
after finish setting. When the knitted fabric was
wound around the human body, bent creases occurred
inside the knitted fabric along the curved line of the
human body, and the creases never disappeared even
after the knitted fabric was recovered to the original
state.
Comparative Example 8
Using a knitting machine same as that of
Example 16, a knitted fabric was knitted with weaves
and conditions same as those of Example 1. At this

time, no polyurethane elastic yarn was used for front
and reserve ground knitted fabrics, and a cover elastic
yarn having a polyurethane elastic yarn of 155
decitexes as a core, around which a polyester core-
sheathing type heat seal yarn of 167 decitexes/16
filaments was wound, was used as a connecting yarn. At
this time, the ratio of the covering draft of the
elastic yarn was 2.5, and the number of twists of the
cover yarn was 300 tiraes/m. Since the connecting yarn
was a cover elastic yarn, a delivering apparatus to be
used when knitting a well known polyurethane elastic
yarn in a bare state, was not used.
For other aspect, the knitted fabric was
knitted and dye finishing was performed in the same
manner as in Example 16. The obtained knitted fabric
had a thickness of 1.4 mm, a knitting density of 14
courses/cm x 11.5 wale/cm, total connection number per
square cm of 161, connecting yarn total decitexes per
square cm of 24,955 decitexes, and D/T of 17,825. This
elastic knitted fabric had a compressibility of 58%, a
recovery rate of 72.0%, and an air flow resistance of
0.14 kPa—s/m.
This knitted fabric had a small air flow
resistance, but was so poor in compression
recoverability in the thickness direction that plastic
deformation occurred by compression. It was not a
knitted fabric desired in the present invention.
Furthermore, the connecting yarn was heat-sealed during

dyeing, thus bringing about a satisfactory level of
binding between the connecting yarn and the ground
knitted fabric, but the heat-sealed part was hard, and
the knitted fabric as a whole had a hard feel, and was
hard to be bent, and the knitted fabric was thus
unsuitable as a knitted fabric to be worn by a person
or used at a location close to the skin as desired in
the present invention. Furthermore, as in the case of
Comparative Example 16, the knitted fabric had a
disadvantage such that the inside ground knitted fabric
was creased as the knitted fabric was bent.
INDUSTRIAL APPLICABILITY
An elastic circular knitted fabric having a
three-layer structure, and an elastic warp knitted
fabric of the present invention are free from curling
such that the year part of the knitted fabric is
curled, excellent in form stability, and excellent in
elongation recoverability, thinness feeling and surface
quality. Furthermore, the present invention can
provide an elastic knitted fabric having a good warp
and weft elongation balance compared with a stretch
gray yarn capable of being manufactured by a single
circular knitting machine or single warp knitting
machine of the prior art, and being most suitable for
underwear, foundations, sport wear, supporters and the
like. Furthermore, the size of polyurethane based
elastic fibers can be selected and applied for each

fabric having unprecedented stretchability in shape
supplement applications.
An elastic circular knitted fabric having a
three-dimensional structure, and an elastic warp
knitted fabric of the present invention are suitably
used for shoe materials such as pad materials in shoes,
upper materials for shoes and boots and slippers, bag
materials such as bag fabrics and protection cases for
glasses and cellular phones, pats such as bed pats,
brassiere pats and shoulder pats, cover materials such
as pillow covers, masks such as masks, eye masks and
face masks, medical sub materials such as supporters,
wound protection materials, protectors and diaper
covers, leg materials such as tights, socks and leg
warmers, sport cloths such as protective shorts,
sliding shorts and jump shorts, underwear such as
thermal insulation inners and tensile outer garments
such as jumpers.













WE CLAIM
1. An elastic knitted fabric having a multilayer structure which is made by
binding together separate front and back two-layer ground knitted fabrics
(1,2,4,5,7,8,16,17) which are formed by two needle beds, wherein at least
one of the ground knitted fabrics form stitches in a state in which
polyurethane based elastic fibers (20,21,22,23) as a bare string (s) and a
non-elastic yarn (6) are arranged and said two-layer ground knitted
fabrics are bound with only a polyurethane based elastic fiber bare string
(s) of 17 to 3000 decitexes.
2. The elastic knitted fabric as claimed in claim 1, wherein said elastic knitted
fabric is a circular knitted fabric with the separate front and back ground
knitted fabrics each formed by one needle bed, the ground knitted fabrics
being bound together by a tuck loop of only a binding yarn(s) constituted
by a polyurethane based elastic fiber bare string^) of 33 to 3000
decitexes, wherein either of said separate front and back ground knitted
fabrics has a smaller loop length than the other, the binding yam(s) is
bound to 25% or more of stitches of one of the separate front and back
ground knitted fabrics having a lower stitch density, a ratio of the loop
length of the binding yarn(s) to the loop length of the one of said
separate front and back ground knitted fabrics having a smaller loop
length is in a range of 0.6 to 2.3, and the elastic knitted fabric has an air
gap between the front and back ground knitted fabrics and has a three
dimensional structure.

3. The elastic knitted fabric as claimed in claim 1, wherein said elastic knitted
fabric is a circular knitted fabric with the separate front and back ground
knitted fabrics each formed by one needle bed, the ground knitted fabrics
being bound together with only a binding yarn(s) constituted by a
polyurethane based elastic fiber bare string(s) of 17 to 1500 decitexes,
wherein either of said separate front and back ground knitted fabrics has
a smaller loop length than the other, at least one of the ground knitted
fabrics is bound by a tuck loop to the binding yarn(s), the binding yarn(s)
is bound to 25% or more of stitches of one of the separate front and back
ground knitted fabrics having a lower stitch density, a ratio of the loop
length of the binding yarn(s) to the loop length of the one of said
separate front and back ground knitted fabrics having a smaller loop
length Is in a range of 0.2 to 0.6, and the elastic knitted fabric has a
three-layer structure.
4. The elastic knitted fabric as claimed in claim 1, wherein each of said
ground knitted fabrics has a warp-knitted structure, either of said separate
front and back ground knitted fabrics has a nailer loop length than the
other, and said binding yarn(s) is bound to 25% or more of stitches of
one of the separate front and back ground knitted fabrics having a lower
stitch density.
5. The elastic knitted fabric as claimed in any one of claims 1 to 4, wherein
at least one of the ground knitted fabrics contains an elastic composite
yarn.

6. The elastic knitted fabric as claimed in any one of claims 1 to 4, wherein
both the front and back ground knitted fabrics form stitches in a state in
which polyurethane based elastic fibers as a bare string and a non-elastic
yarn are arranged.
7. The elastic knitted fabric as claimed in one of claims 1 to 4, wherein the
size of the polyurethane based elastic fibers in the at least one ground
knitted fabric is (D-g), and the size of the polyurethane based elastic
fibers in the bare string(s) of the binding yarn(s) is (D-c), and the ratio
(D-c/D-g) ≥ 2 is satisfied.
8. The elastic knitted fabric as claimed in any one of claims 1, 2, or 4,
wherein the ratio of the gross size of a binding yarn(s) for binding 1
cm.sup.2 of ground knitted fabric: D (decitex) to the thickness of the
elastic knitted fabric: T (mm) is:
5x103≤D/T≤5x105.
9. The elastic knitted fabric as claimed in claim 6, wherein the elongations in
warp and weft directions are each 80 to 150% under a load of 3.5 N/cm
and 100 to 200% under a load of 9.8 N/cm, an elongation ratio(A) and an
elongation ratio (B) in warp and weft directions, expressed by the
following equations (1) and (2) are each in a range of 0.6 to 1.2:

elongation ratio (A)=elongation (%) in warp direction under load of 3.5
N/cm  elongation in weft direction (%); (1)
elongation ratio (B)=elongation (%) in warp direction under load of 9.8
N/cm  elongation in weft direction (%).
10.The elastic knitted fabric as claimed in any one of claims 1 to 4, wherein
the elastic knitted fabric has a recessed portion or raised portion formed
and fixed by heat molding, and has a three-dimensional structure.
11.The elastic knitted fabric as claimed in claim 10, wherein the volume
retaining factor of a mold molded by heat molding, defined below, is 0.5
or greater:
volume retaining factor=(molding volume retained by molded elastic
knitted fabric)/heat molding volume).
12.The elastic knitted fabric as claimed in any one of claims 1 to 4, wherein
two or more types of non-elastic yarns are used in at least one of the
ground knitted fabrics, and a jacquard pattern is provided by the two or
more types of non-elastic yarns.

13.The elastic knitted fabric as claimed in claim 2 or 4, wherein a part of the
elastic knitted fabric having a three-dimensional structure and an air gap
between the front and back two ground knitted fabrics is bound in a
contact state with a non-elastic yarn forming a part of the binding yarn(s)
and/or a ground knitted fabric.
14. A molded cloth, at least part of which is formed by a non-sewn cylindrical
circular knitted fabric, wherein the cylindrical circular knitted fabric is the
elastic knitted fabric as claimed in any one of claims 1 to 4.
15. A process for manufacturing the elastic knitted fabric as claimed in any
one of claims 1 to 4, comprising knitting a knitted fabric containing an
elastic yarn by a circular knitting machine, wherein a feed speed (V-g) of
a bare string of polyurethane based elastic fibers for knitting a ground
knitted fabric is unequal to a feed speed (V-c) of a bare string of
polyurethane based elastic fibers of the binding yam(s) for binding the
front and back ground knitted fabrics.
16.The process as claimed in claim 15, wherein the bare string of
polyurethane based elastic fibers of the binding yarn(s) for binding the
front and back two-layer ground knitted fabrics is fed at a controlled draw
ratio of 2 or less.

The invention relates to an elastic fabric having a
multilayer structure which is made by binding together separate
front and back two-layer ground knitted fabrics
(1,2,4,5,7,8,16,17) which are formed by two needle beds, wherein
at least one of the ground knitted fabrics form stitches in a
state in which polyurethane based elastic fibers (20, 21,22, 23)
as a bare string (s) and a non-elastic yarn (6) are arranged and
said two-layer ground knitted fabrics are bound with only a
polyurethane based elastic fiber bare string (s) of 17 to 3000
decitexes.

Documents:

554-KOLNP-2004-FORM-27.pdf

554-kolnp-2004-granted-abstract.pdf

554-kolnp-2004-granted-claims.pdf

554-kolnp-2004-granted-correspondence.pdf

554-kolnp-2004-granted-description (complete).pdf

554-kolnp-2004-granted-drawings.pdf

554-kolnp-2004-granted-examination report.pdf

554-kolnp-2004-granted-form 1.pdf

554-kolnp-2004-granted-form 18.pdf

554-kolnp-2004-granted-form 2.pdf

554-kolnp-2004-granted-form 26.pdf

554-kolnp-2004-granted-form 3.pdf

554-kolnp-2004-granted-form 5.pdf

554-kolnp-2004-granted-reply to examination report.pdf

554-kolnp-2004-granted-specification.pdf


Patent Number 228092
Indian Patent Application Number 554/KOLNP/2004
PG Journal Number 05/2009
Publication Date 30-Jan-2009
Grant Date 28-Jan-2009
Date of Filing 27-Apr-2004
Name of Patentee ASAHI KASEI FIBERS CORPORATION
Applicant Address 2-6 DOJIMAHAMA 1-CHOME 1-CHOME, KITA-KU, OSAKASHI, OSAKA
Inventors:
# Inventor's Name Inventor's Address
1 TOSHIYUKI KONDOU 4-5, HIGASHICHUJOCHO, IBARAKI-SHI, OSAKA
2 TOMOAKI YOSHIDA 1-21-4, KOHOKU, HIRAKATA-SHI, OSAKA
3 KAZUO FURUYA 16-20-3B, MUKODAICHO 1-CHOME, NISHITOKYO-SHI, TOKYO
PCT International Classification Number D04B 1/00
PCT International Application Number PCT/JP02/10675
PCT International Filing date 2002-10-15
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2001-335172 2001-10-31 Japan
2 2002-103403 2002-04-05 Japan
3 2002-178782 2002-06-19 Japan
4 2002-004973 2002-01-11 Japan