CN116761912A - Warp knitted spacer mesh fabric with high breathability, elasticity and support - Google Patents

Abstract

A spacer fabric (10) comprising a first knitted layer (12), a second knitted layer (14) and a third layer (16) comprising monofilament spacer yarns extending between and connecting the first knitted layer (12) and the second knitted layer (14), wherein the first knitted layer (12) has a mesh structure.

Description

Warp knitted spacer mesh fabric with high breathability, elasticity and support

Cross Reference to Related Applications

The present application claims priority from PCT application No. PCT/CN2021/086319 filed on 11/4/2021, which is incorporated herein by reference in its entirety.

Technical Field

One or more embodiments relate to warp knitted spacer fabrics having one or more warp knitted mesh layers, cushion layers made of spacer fabrics, composite materials made of spacer fabrics, decorative covers made of spacer fabrics, and methods of making the same. At least one or more other embodiments relate to warp knit 3D spacer mesh fabrics, and in particular to methods of making warp knit 3D fabrics having high permeability and high elasticity.

Background

Along with the continuous improvement of the living standard of people, the requirements of people on the comfort (softness, elasticity/air permeability) and environmental protection of the automobile seat cushion are also continuously improved. Under conventional car seat cushions, a layer of foam, such as polyurethane foam, is typically used. In some instances, it may be desirable to attempt to inhibit or minimize the use of polyurethane foam.

Spacer fabrics are versatile and therefore useful in many different applications. The spacer fabric is flexible and therefore easy to bend. The spacer fabric may also be breathable. Another feature found in most spacer fabrics is elasticity.

Because of the various advantageous properties of the spacer fabric, the spacer fabric may be used in a variety of applications including, but not limited to: furniture such as seats, mattresses and upholstered items; vehicle parts such as climate and non-climate car seats, trim and seat covers and trim panels, e.g. door panels, instrument panels, consoles and headliners; and wearable articles such as athletic shoes and clothing.

Warp knit 3D mesh fabrics have been increasingly used to replace some or all of the specific uses of polyurethane foam due to their soft elastic and environmentally friendly material properties, however, warp knit 3D mesh fabrics that have been used in the art have been found to have limited and possibly inadequate stability of the intermediate link support monofilaments. In some cases, when the intermediate connecting support monofilaments have been compressed by the upper and lower fabrics of the 3D fabric, it has been found that the intermediate connecting support monofilaments are relatively easy to drop or compress laterally under pressure, resulting in less than ideal elasticity and comfort.

In addition, the spacer fabric may be used as a composite material or a decorative material. Suitable composite materials include spacer fabrics sandwiched between a cover layer (which may be decorative, such as leather, vinyl, or fabric) and a substrate (which may be a rigid or flexible substrate layer).

In at least some embodiments, the present disclosure is directed to overcoming perceived deficiencies of the prior art and providing warp knit 3D fabrics having relatively high breathability and elastic recovery.

Disclosure of Invention

In one embodiment, a spacer fabric is provided that includes a first knitted layer, a second knitted layer, and a third layer including monofilament spacer yarns extending between and connecting the first knitted layer and the second knitted layer to form a unitary three-dimensional network structure. In at least one embodiment, the spacer fabric has a relatively high air permeability.

Generally, the larger the voids (pore size) of the fabric (upper and lower) the better the air volume while ensuring the basic function of the fabric. The comfort and support of the spacer fabric is related to its elasticity and recovery. This is also related to the stiffness of the connecting filaments and the ability of the upper and lower fabrics to retain the connecting filaments. In at least one embodiment, the first layer is a mesh layer forming the upper fabric and the second layer is a plain cloth or substantially solid layer forming the lower fabric, wherein the first and second layers have a unique structure. These structures not only ensure good gripping and attachment of the filaments, but also have good breathability.

Drawings

FIG. 1 is a schematic perspective view of a spacer fabric according to an embodiment of the present disclosure;

FIG. 2 is a photograph of an embodiment of the spacer fabric of FIG. 1;

FIG. 3 is an enlarged exploded view of an embodiment of a spacer fabric, schematically showing details of an embodiment of a spacer fabric layer;

FIG. 4 is a photograph at 10 magnification of an embodiment of a first layer of mesh fabric;

FIG. 5 is a schematic digital picture of an embodiment of a first layer mesh structure;

FIGS. 6A and 6B are illustrations of first layer yarn movement of an embodiment of a first layer mesh fabric;

FIG. 7 is a representation of the movement of the first layer yarns of an embodiment of the first layer fabric;

FIG. 8 is a representation of first layer yarn movement of an embodiment of the first layer mesh fabric;

FIG. 9 is a photograph at 10 magnification of an embodiment of a second layer scrim;

FIG. 10 is a single yarn movement chart illustrating movement of yarn in a second layer of the fabric;

FIG. 11 is a representation of a second layer yarn movement of an embodiment of a second layer of the fabric;

FIG. 12 is a warp knit view of a 3D spacer mesh fabric;

FIG. 13 is an illustration of first layer yarn movement of the first layer mesh fabric according to another embodiment;

FIG. 14 is an illustration of first layer yarn movement of a first layer fabric according to another embodiment;

fig. 15 is an illustration of first layer yarn movement of a first layer mesh fabric according to another embodiment; and

fig. 16 is a photograph of a first layer of mesh fabric at 10X magnification according to another embodiment.

Detailed Description

As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

Referring to fig. 1 and 2, a representative spacer fabric 10 of the present disclosure is illustrated. Spacer fabric 10 may be used in a variety of applications. In certain embodiments, spacer fabric 10 may be used as a seat cushion with or without a corresponding foam layer, such as a polyurethane foam layer. The spacer fabric 10 may be used as a seat cushion or seat cushion component in any seat cushion application, such as a seat bottom, a seat back, and/or a trim panel.

In other embodiments, the spacer fabric 10 may be used as a decorative layer component, with the spacer fabric 10 secured under the decorative layer. In such embodiments, any suitable decorative layer may be used, such as, but not limited to, leather, synthetic leather, plastic (e.g., vinyl), and textile layers. The decorative or decorative layer may be secured to the spacer fabric 10 by any suitable technique (e.g., by stitching or adhesive).

In other embodiments, spacer fabric 10 may be used as a composite material requiring some elasticity and/or breathability. It should be readily appreciated that the composite made using spacer fabric 10 of the present disclosure may be other automotive or non-automotive composites.

As schematically shown in fig. 1-3, the spacer fabric 10 has a mesh-like first knit layer 12, a generally solid or closed (i.e., plain) second knit layer 14, and spacer yarns 16 extending between and connecting the first knit layer 12 and the second knit layer 14.

In certain other embodiments, the spacer fabric 10 comprises a warp knit 3D mesh fabric having a warp knit mesh fabric upper layer 12, a warp knit (non-mesh) lower layer 14, and monofilaments 16 knitted into the upper and lower layers 12, 14 to form a unitary three-dimensional network structure 10.

In certain other embodiments, and as will be described in greater detail below, the spacer fabric 10 of the present disclosure has relatively high breathability, elasticity, and support as compared to other fabrics. In this regard, the spacer fabric 10 of the present disclosure is particularly well suited for use in the lower seat cushion material of an automotive seat. In at least some embodiments, the web forming the upper fabric 12 and the scrim forming the lower fabric 14 have unique structures, which are representatively illustrated in the figures.

In certain embodiments, the two knit layers 12 and 14 have wales (stitchwales) extending in the production direction and courses (stitchcourses) extending in the transverse direction. The spacing yarns 16 extending between and connecting the first knit layer 12 and the second knit layer 14 can be any suitable monofilament yarns.

In certain other embodiments, the upper layer 12 and the bottom layer 14 are made of a common multi-ply polyester yarn. In at least one embodiment, the upper layer 12 and the lower layer 14 are made of a common multi-ply polyester yarn of size 83dtex/36F and an intermediate linking monofilament 16 of size 33-44 dtex/1F. It should be understood that other sizes and/or types of yarns may be used and still be consistent with the present disclosure.

In at least some other embodiments, the interlaminar yarns 16 should have good stiffness and elasticity. In certain other embodiments, the size and thickness of the monofilaments may be selected based on the desired compressive strength and the desired rebound deformation characteristics to be achieved. In at least some other embodiments, the monofilament yarns 16 have a size of 33-44dtex. It should be understood that other sizes and/or types of monofilaments may be used and still be consistent with the present disclosure.

As best seen in fig. 4 and 5, the first layer 12 has openings 8. In at least some embodiments, the openings in the upper layer 12 are shown as being generally oval in shape, however, the openings 8 may be any suitable shape, such as elongated, circular, square, and/or rectangular, to name a few. The size of the opening 8 of the upper layer 12 may be adjusted to any suitable size as desired. In general, the larger the opening 8, the better the air amount, however, the support will decrease as the size of the opening 8 increases. In at least one embodiment, the upper layer 12 has a higher air permeability than the lower layer 14.

An image of an exemplary embodiment of the first knit layer 12 is shown in fig. 5. In the figures, it can be seen that the first knitted layer 12 has an open mesh structure. As representatively shown in the illustrated embodiment, the open mesh structure of the first knit layer 12 has fabric strips 6 separated by a plurality of spaced apart openings 8.

In at least the illustrated embodiment, the openings 8 are generally oval and extend in offset and staggered rows. In at least one embodiment, the openings 8 are spaced apart in staggered rows. In at least one embodiment, the openings 8 are centrally spaced apart by 0.5 to 10mm in the width direction and centrally spaced apart by 0.5 to 10mm in the length direction.

As schematically shown in one embodiment in fig. 3 and 12, the spacer fabric 10 may be produced by a double needle bar warp knitting machine. As shown schematically and representatively, five pattern bars 11, 13, 15, 17 and 19 may be used to guide yarns 21, 23, 25, 27 and 29 to needles 31 and 33. The flower bars 17 and 19 may be used to guide yarns 21 and 22 to needles 31 for knitting the first mesh fabric layer 12. The flower bars 13 and 15 are used to guide the yarns 25 and 27 to the needles 31 and 33 for knitting the support monofilament 16. The pattern bar 11 is used to guide the yarn 29 to the needles 33 for knitting the underlying fabric 14.

The first layer 12 has an open mesh structure, as schematically shown in fig. 4 and 12. FIGS. 6A and 6B illustrate an embodiment of a suitable single yarn backing movement chart for two flower bars. The yarn-laying motion diagram is the loop formed by the needle from bottom to top. The horizontal dot columns are used to represent the needles arranged in sequence on the needle bed. The top of the dot 22 represents the front of the hook and the bottom of the dot 22 represents the rear of the needle. Yarn 21 oscillates through the bar 19 to complete the hooking of needle 31 into the backing yarn and the reverse shogging of needle 31. This law of motion is shown in the motion curves of yarns 21 and 23 in fig. 6A and 6B. In the same way, the yarn 23 completes the filling movement described above by means of the pattern bar 17.

As representatively illustrated in fig. 6A and 6B, for the first layer 12 of the fabric yarn-laying motion diagram, the yarn-laying motion diagram shows loops formed sequentially from bottom to top by needles, with a line of dots (shown at 22). The points in the transverse direction are used to indicate the needles (N1/N2/N3/N4/N5/N6/N7/N8 … …) arranged in sequence, with the upper part of the point 22 indicating the front of the needle hook and the lower part of the point 22 indicating the rear of the needle. The continuous line segment is used to represent the movement of the guide needle of the pattern bar in front of the needle and behind the needle. Typically, the number of fills (digitized) is 0, 1, 2, 3, 4, 5, 6, 7, 8 … … in the order from right to left between the needles and is used to represent the movement trace of the flower bar. c1-C12 … … represent rows C formed by looping the yarn from bottom to top. Arrow 47, etc. indicates the direction of movement of the yarn 23 guided through the bar 17. The law of motion of all the yarns on the pattern bar 17 is the same, and the yarn 23 is at least the embodiment shown, however, it should be understood that other laws of motion may be employed. In the embodiment shown, in fig. 6, the needle bar formation of one flower bar 17 is recorded as: 1-0/1-2/1-0/1-2/7-8/7-6/7-8/7-6//, where "1-0" corresponds to 39 in the C1 course, "1-2" corresponds to 40 in the C2 course, where "1-0" corresponds to 41 in the C3 course, "1-2" corresponds to 42 in the C4 course, "7-8" corresponds to 43 in the C5 course, "7-6" corresponds to 44 in the C6 course, where "7-8" corresponds to 45 in the C7 course, "7-6" corresponds to 46 in the C8 course. The yarn-packing movement of the pattern bar 19 is completely symmetrical to the yarn-packing movement of the pattern bar 17. The backing yarn of the pattern bar 19 is recorded in the embodiment shown as: 7-8/7-6/7-8/7-6/1-0/1-2/1-0/1-2//. The numbers indicate that the mesh needle of one of the bars is being formed and that the two bars work together to create the mesh pattern. In addition, the main explanation of all the filling motion diagrams below is the same as in this section, the only difference being the rule of motion of the filling.

The first layer 12 has an open mesh structure as shown in the embodiments shown in fig. 4, 7 and 8. In the embodiment shown in fig. 7, the movement diagram of a single bar shows that the threading of the yarn on the same bar is regular by a series of three consecutive threads 51 separated by a gap 53 of the cycle, and that there is no yarn connected between the two longitudinal directions of the hollow portion so as to form the mesh opening 8. In this embodiment, the yarn is in a regular three-in one-out threading pattern repeated on the machine. It should be understood that some may fall outside the ranges described above and illustrated and still be consistent with the present disclosure.

As shown in the illustrated embodiment, the yarns 21 and 23 on the two flower bars are symmetrically directed towards the needle hook according to the law of movement of fig. 6A, 6B and 8. In at least one embodiment, the loops in adjacent longitudinal threads are not connected and they are inclined in opposite directions to form mesh openings 8 (as shown in fig. 4 and 8), and the loops on adjacent longitudinal threads are connected and adjacent to each other to form fabric strip 6. The open mesh construction of the first knit layer 12 has a plurality of openings 8 and fabric strips 6. In at least one embodiment, the openings 8 have four courses in length, as shown in the example of fig. 8, but it should be understood that the openings 8 may have any suitable size that can be increased or decreased as needed, particularly according to the desired level of breathability, corresponding to the number of coils. In at least one embodiment, fabric strip 6 has four wales in width (as shown in the example of fig. 4 and 8) and four courses in length between the mesh openings (as shown in the example of fig. 6), but may have any suitable dimensions. While most, if not all, openings fall within the above ranges, it should be understood that some may fall outside of the above ranges and still be consistent with the present disclosure.

A second embodiment of the first layer 12 having an open mesh structure is schematically shown in fig. 13-16. In the embodiment shown in fig. 14, the movement diagram of a single bar shows that the threading rule of the yarn on the same bar is a series of three threads 26 separated by a gap 61 of the cycle. As shown in this embodiment, there are no connecting yarns between the two longitudinal directions of the hollow portion to form mesh openings 63. It should be understood that some may fall outside the above ranges and still be consistent with the present disclosure.

In the embodiment of the first layer 12 with open mesh structure shown in fig. 13 to 16, the yarns 30 and 71 on the two flower bars are symmetrically directed towards the hooks according to the movement rules of fig. 13 and 15. In at least one embodiment, the loops in adjacent longitudinal threads are not connected and they are inclined in opposite directions to form mesh openings 63 (as shown in fig. 15 and 16), and the loops in adjacent longitudinal threads are connected and adjacent to each other to form fabric strip 28. The open mesh construction of the first knit layer 12 has a plurality of openings 63 and fabric strips 28. In at least this embodiment, the openings 63 have six courses in length, as shown in the example of fig. 15, but the openings 29 may have any suitable size that can be increased or decreased as needed, particularly according to the desired level of breathability, corresponding to the number of coils. In at least this embodiment, the fabric strip 28 has four wales (as shown in the example of fig. 15 and 16), and six courses in width (as shown at 67 in the example of fig. 13). However, it should be understood that the length between the meshes may have any suitable dimensions. While most, if not all, openings fall within the above ranges, it should be understood that some may fall outside of the above ranges and still be consistent with the present disclosure.

An embodiment of the second layer structure 14 is shown in fig. 9 to 11. As shown in the example of fig. 12, a single bar directs the entire thread to the needle needles such that each needle is covered with yarn, thereby knitting the yarn with each needle.

In the embodiment of the second layer structure 14 shown in fig. 9 to 11, and in the example shown in fig. 12, the flower bar 11 drives the yarn 29 to guide it into the hook 33 according to the law of motion 69 in fig. 10. An embodiment of a knitted fabric is shown in fig. 9.

In the second layer structure 14 shown in the embodiment of fig. 9-11, the fabric structure of this layer is a generally solid (i.e., no mesh generation) warp plain weave that spans two or more needles, and a single flower bar directs yarns to the needles according to the embodiment shown in fig. 10 and 11. The length of the extension 38 is related to the transverse density of the fabric and also to the number of needles that pass when feeding the yarn, the more needles that pass or the smaller the transverse density of the fabric, the longer the corresponding extension 38.

It should be noted that the prior art methods generally use two flower bars to guide the yarn, which makes the structure very stiff and less elastic. In at least one embodiment of making the second layer structure 14 of the present disclosure, a single flower bar is used to make the structure soft and resilient. The length of extension 38 shown in fig. 9 and 10 helps determine the elasticity of the fabric.

In the intermediate connecting monofilament 16 shown in fig. 1 to 3 and 12, in at least the embodiment shown in fig. 12, the two flower bars 13 and 15 drive the yarns 25 and 27 to guide the yarns into the hooks 31 and 33.

In the intermediate connecting monofilament 16 structure shown in fig. 1-3 with the first and second knitted layers 12, 14, in at least the illustrated embodiment, the two flower bars are symmetrical fill yarns that participate in the knitting of the first and second layers 12, 14, respectively. Thus, the monofilament 16 may be intimately bonded with the two knitted layers 12 and 14 to form the 3D network structure 10. The first and second knitted layers 12 and 14 can securely hold and connect the monofilaments 16 by the structure of 6 and 14 in fig. 4 and 9 such that the connecting monofilaments 16 are securely held and fixed. In at least one embodiment, the thickness of the 3D spacer mesh fabric may be determined by the length of the connecting filaments 16. In at least one embodiment, the fabric thickness is 9-10mm, but it should be understood that this is just one example and the present disclosure can adjust the thickness as desired.

In at least some other embodiments, to achieve a soft, comfortable, elastic, and breathable spacer fabric 10, the layers (and in some embodiments, the upper layer 12) are provided with fabric layer spacing arranged through the mesh openings 8 and the flat pattern 6, enabling the mesh to provide the fabric with excellent breathability. In certain embodiments, the mesh size may be adjusted according to desired ventilation requirements. The plain weave portion helps to make the intermediate connecting monofilaments 16 and the upper fabric 12 more stable and strong. Thus, the stability and flatness of the intermediate connecting filaments 16 may be relatively good and the filaments are inhibited from becoming canted and/or bunched. Due to the mesh, the monofilaments 16 can be distributed relatively uniformly and the forces can be distributed over a relatively large surface area and help avoid localized collapse. In at least some other embodiments, the monofilaments have good stability due to plain weave consolidation, so that they do not readily drop in the cross-machine direction, and the elastic recovery of the fabric can be improved relative to other fabrics.

In at least one embodiment, the spacer fabric 10 has a thickness of 8-12mm, in another embodiment 8.5-11mm, and in yet another embodiment 10mm.

The elasticity and support of the 3D spacer fabric 10 is related to the stiffness of the monofilaments 16 and the fabric's structure and vertical and horizontal densities. The upper fabric structure 12 and the lower fabric structure 14 described above are capable of holding the connecting filaments 16 well, thereby helping to inhibit the filaments 16 from falling sideways under external pressure, which helps to inhibit the fabric from deteriorating in elasticity and support. In addition, if the stiffness of the intermediate connecting monofilaments 16 is too great or too small, the elasticity and comfort of the fabric may be poor. As the vertical and horizontal densities of the fabric increase, the support will be stronger. In at least one embodiment, the elasticity and support of the fabric is measured by, but not limited to, a compressive stress value of 5±2 KPa. In at least one embodiment, the spacer fabric 10 of the present disclosure has a compressive stress value of about 4.2 KPa. The compressive stress value can be measured by the following test method: DIN EN ISO 3386-1, 0.1Pa preloaded (Vorkraft); 80x80mm/100mm/min.

The high air permeability of the 3D spacer fabric 10 is related to the gap between the upper fabric 12 and the lower fabric 14. Generally, the larger the gap, the better the breathability, but the size of the fabric gap can limit elasticity and support. In at least one embodiment, the air permeability of spacer fabric 10 is typically greater than or equal to 3500mm/s, but is not limited to this value. In at least one embodiment, the spacer fabric 10 of the present disclosure has a breathability of about 5000 mm/s. The air permeability can be measured by the following test method: DIN EN ISO 9237 mbar, test specimen: 20cm ² 。

While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, features of various implementing embodiments may be combined to form further embodiments of the disclosure.

Claims (20)

1. A spacer fabric, comprising:

a first knit layer;

a second knit layer; and

a spacing yarn extending between and connecting the first and second knitted layers,

the first knitted layer has a mesh structure including a plurality of spaced openings separated by a plain weave portion,

the second knitted layer has a plain weave structure;

wherein the spacer fabric has a compressive stress value of 5+ -2 KPa and an air permeability of 3500mm/s or more.

2. The spacer textile of claim 1, wherein the first layer has openings spaced apart in offset rows.

3. Spacer textile according to claim 2, wherein the openings are substantially circular, elongated, oval, square and/or rectangular in shape.

4. A spacer fabric according to claim 3, wherein the openings are centrally spaced apart in the width direction by 0.5 to 10mm and centrally spaced apart in the length direction by 0.5 to 10mm.

5. The spacer textile of claim 1, wherein the first and second knitted layers together with the spacer yarns form a unitary three-dimensional network structure.

6. The spacer textile of claim 1, wherein the spacer textile comprises a cushion layer in a vehicle seat trim cover.

7. The spacer textile of claim 1, wherein the upper layer has a higher air permeability than the lower layer.

8. The spacer fabric of claim 1 wherein the first layer comprises a series of three threads separated by thread-sized voids.

9. The spacer fabric of claim 1 wherein each opening of the first layer is separated by three yarns.

10. The spacer fabric of claim 1, wherein each of the plain weave fabric portions is made of three yarns.

11. The spacer textile of claim 1, wherein each of the plurality of openings comprises one wale in width and four courses in length.

12. The spacer fabric of claim 11 wherein each fabric portion comprises four wales in width and four courses in length.

13. The spacer textile of claim 1, wherein each of the plurality of openings comprises one wale in width and six courses in length.

14. The spacer fabric of claim 13 wherein each fabric portion comprises four wales in width and six courses in length.

15. A spacer fabric, comprising:

a first knit layer;

a second knit layer; and

a spacer yarn extending between and connecting the first and second knitted layers,

the first knitted layer having a mesh structure comprising a plurality of spaced apart openings separated by fabric portions,

wherein each of the plurality of openings comprises a column in width and at least four courses in length.

16. The spacer textile of claim 15, wherein each of the plurality of openings comprises six courses in length.

17. The spacer fabric of claim 11 wherein each fabric portion comprises four wales in width and at least four courses in length.

18. The spacer textile of claim 17, wherein each textile portion comprises six courses in length.

19. Spacer fabric according to claim 15, wherein the spacer fabric has a compressive stress value of 5±2KPa and a gas permeability of 3500mm/s or more.

20. Spacer fabric according to claim 15, wherein the spacer fabric has a thickness of 8-12mm.