DE102019128999A1 - Flat weave with two layers - Google Patents

Abstract

A fabric is provided, preferably for use in a motor vehicle, the fabric having an upper fabric and a lower fabric connected to it, the lower fabric being a flame-retardant fabric.

Description

Technical area

The present invention relates to a (flat) fabric with two layers, in particular a flat fabric for use in a motor vehicle, for example as a seat cover, a seat with the fabric and a method for producing the fabric.

State of the art

Two different types of fabrics are currently used in motor vehicles with the ECE 118.03 requirement, e.g. as seat covers: single-layer flat fabrics made of polyester with a FR coating applied to the back and woven velours with a pile made of 100% FR yarns (FR = fire resistant or flame retardant).

A flat weave is created by crossing two thread systems at right angles (warp & weft). The warp threads run perpendicular to the machine or the reed and the weft threads parallel to the machine / the reed.

A woven velor is a fabric that has a "fluffy" surface. This surface is created by so-called pile threads, which are cut to an even length.

All fabrics used in motor vehicles (e.g. class M3) must be flame retardant in order to meet the respective approval requirements, such as required for ECE homologation (e.g. ECE standard 118.03).

More precisely, in accordance with ECE standard 118.03, materials and composite materials that are installed more than 500 mm above a seat cushion and in the vehicle roof must be subjected to the test in accordance with Annex 7 (melting behavior). The test result is considered to be satisfactory if, taking into account the most unfavorable test results, no drop forms that ignites the (test) cotton wool.

In addition, materials and composite materials that are installed vertically in the passenger compartment must be subjected to the test in accordance with Annex 8 (vertical reaction to fire). The test result is considered to be satisfactory if, taking into account the most unfavorable test results, the vertical burning speed does not exceed 100 mm / minute or the flame goes out before the first marker thread is destroyed.

In addition, the automobile manufacturers themselves also place high demands on the substances installed in the motor vehicle, in particular on their durability. This wear requirement can be: 50,000 to 60,000 tours according to Martindale DIN / EN / ISO 12947-2 , no thread breakage, no hole formation and no white chafing. The Martindale method simulates the natural wear and tear of a seat cover by rubbing a sample of the material to be tested with a given weight against a standard woolen material. In this test, the textiles to be tested are rubbed against a specified wool fabric in a repeating figure ("Lissajous"). After the required number of revolutions has been reached (at least 50,000 cycles), thread breaks, hole formation and white chafing are checked and evaluated.

Disadvantages of the flat fabric made of 100% FR yarns compared to a comparable fabric made of standard polyester is a deterioration in the wear behavior (Martindale).

Disadvantages of the FR coating on the back are the high emission values due to the use of FR chemicals, additional work steps and a significantly firmer grip or a changed feel of the coated fabric compared to the non-coated fabric.

It is an object of the present invention to provide a fabric which is suitable for use in a motor vehicle (e.g. class M3), for example as a seat cover, and which overcomes the above disadvantages of the prior art.

Summary of the invention

This object is achieved by the features of the independent claims. Further advantageous configurations are listed in the dependent claims.

A fabric is provided, preferably for use in a motor vehicle, the fabric having two layers, i.e. an upper fabric and a flame-retardant lower fabric connected to the upper fabric. The upper fabric meets the wear requirements and the lower fabric ensures that the entire fabric meets the requirements for flame retardancy.

The motor vehicle can be one of class M3 (vehicles for passenger transport with more than eight seats in addition to the driver's seat and a permissible total weight of more than 5 tons).

The upper fabric is that part of the fabric which, when used in a motor vehicle, faces the interior of the vehicle. The sub-fabric is that part of the fabric which, when used in a motor vehicle, forms the interior of the vehicle is turned away. The lower fabric is preferably connected to the upper fabric in such a way that it cannot be perceived by the human eye from the interior of the vehicle.

A flame-retardant fabric is a fabric that does not ignite or only ignites with great difficulty under the influence of a flame, i.e. does not burn faster or burns at a burning rate of less than 100 mm per minute. The goal in developing a flame-retardant fabric is to meet the particularly high requirements of ECE standard 118.03 according to Annex 6, 7 and 8. Annex 6 of ECE standard 118.03 corresponds to a horizontal fire test, whereby a burning speed of the entire fabric is really less than 100mm / must be min. Annex 7 of the ECE standard 118.03 corresponds to a melt test, whereby the material or the fabric here is heated and if drops form, the drops falling down must not ignite the test cotton underneath. Annex 8 corresponds to a vertical fire test, whereby a fire rate of the entire fabric must be really less than 100mm / min. These test objectives can be achieved by the solution according to the invention.

The advantage of this invention is, in particular, that the lower fabric reduces the burning rate of the entire fabric, while it is protected by the upper fabric and is essentially not subject to wear and tear.

The fabric can be a (multi-layer) flat fabric. As stated at the beginning, a flat woven fabric has a crossing of two right-angled thread systems (warp & weft).

The outer fabric can have polyester (PES), polyamide (PA), wool, polyurethane (PU) and / or cellulosic fibers. The upper fabric can consist of one of the aforementioned or consist of a mixture thereof.

The invention also relates to a seat cover having the fabric described above. This is preferably sewn from the fabric described above in such a way that it fulfills the ECE standard 118.03. The seat cover can also have a foam / fleece lamination and other materials such as sewing thread, Velcro and / or OKE strips.

Further advantageous locations for using the fabric are the center of the seat and the side trim. The fabric can also be installed on the headrest, the armrest or on the door side panel.

The invention also relates to a seat with the fabric described above. The seat is preferably a seat of a motor vehicle. The fabric is preferably a seat cover for the seat.

• 1 zeigt ein Flachgewebe bzw. Mehrlagengewebe gemäß einer Ausführungsform von oben.
• 2 zeigt das Flachgewebe aus 1 von unten.
• 3 zeigt das Flachgewebe aus 1 und 2 als Seitenansicht.

The invention also relates to a method for producing the fabric described above, in which, if necessary, the warp thread tension is controlled via two differently controlled warp beams. A warp yarn of the upper fabric and a warp yarn of the lower fabric are preferably fed simultaneously with independently controlled tension during weaving of the fabric. The method can also be used to produce the seat cover described above.

• 1 shows a flat fabric or multi-layer fabric according to an embodiment from above.
• 2 shows the flat weave 1 from underneath.
• 3 shows the flat weave 1 and 2 as a side view.

The following is the flat weave 1 In reference to 1 to 3 described in detail.

1 shows an exemplary construction of the right side of the fabric (upper fabric 2 ) of the flat weave 1 . 2 shows an exemplary construction of the left side of the fabric (lower fabric 3 ) of the flat weave 1 . 3 shows a side view of the flat fabric 1 .

The flat weave 1 has two layers of fabric, namely an upper fabric 2 and a sub-fabric 3 , on. The upper and lower fabric 2 , 3 are like in particular 3 shows, connected to each other by (specifically used) attachment and setting points. The attachment and binding points are chosen so that the upper and lower fabric 2 , 3 sufficiently connected to each other and on the surface, ie in a case as in 1 shown view of the flat weave 1 , are not (annoyingly) visible to the human eye. The density of the attachment and setting points depends on the degree of crossover in the fabric layers 2 , 3 and is on a pattern of the upper fabric 2 Voted. The pattern of the flat weave 1 takes place through a bond in the upper fabric 2 . The density of the attachment and setting points is chosen so that the positive property (flame retardancy) of the sub-fabric 3 the poorer behavior of the upper fabric in this regard 2 compensated.

In a preferred embodiment, the upper fabric has 2 PES and / or PA on. The sub-tissue 3 consists in a preferred embodiment of FR PES. In particular, the upper fabric 2 consist of PES or a mixture of PES and PA (e.g. flock granulate). In particular, the lower fabric can consist of FR PES.

Any fabric layer 2 , 3 each has two thread systems arranged essentially perpendicular to one another, namely warp and weft. Warp threads, which form the warp, run perpendicular to the machine or a reed and weft threads, which form the weft, run parallel to the machine or the reed.

The upper fabric 2 takes over at the flat weave 1 two tasks, on the one hand it determines the visual appearance of the flat woven fabric 1 and on the other hand, it is wear-resistant. The upper fabric 2 consequently meets certain technical requirements for wear behavior. The sub-tissue 3 however, it is flame retardant and reduces the flammability of the entire flat fabric 1 .

A method for producing the flat woven fabric described above is also described below 1 described.

First, the warp yarn is warped on the warping machine. After warping, the entire thread sheet is transferred to a warp beam or tree. This warp beam with its warp threads is then either prepared in the passing shop for the loom, i.e. the threads are drawn into a heald and lamellar system and a reed, or tied to an existing chain with the same setting in the loom.

In a conventional manufacturing process for a flat woven fabric, only one warp beam (not shown) is generally used. Depending on the design specifications of the upper fabric 2 There may be differences in tension between the two chain systems. Different tensions can arise in the warp yarn depending on the type of weave and the arrangement of the tie-in and tie-off points. Certain warp threads can continuously lose tension and sag in the thread composite. In extreme cases, this can lead to a warp thread monitor (not shown) of a weaving machine (not shown) during the production of the flat fabric described above 1 continuously signals a warp thread break and thus triggers the standstill of the weaving machine. The flat weave described above 1 is then not weavable or manufacturable. The quality of the conventionally produced flat woven fabric would not be sufficient.

By using a second warp beam, the two different warp systems, ie the warp of the upper fabric 2 and the chain of the sub-fabric 3 , be sharpened and tree-lined separately.

Both warp systems are then fed to the loom at the same time with constant tension during weaving. Despite the special nature of the construction, this leads to a balanced quality of the flat woven fabric 1 .

• Garn 80%PA, 20%PES FR, Bindung Atlas, Schussaustausch, Kettdichte 27 Fäden PA (±3)/1cm, Schussdichte 13 Fäden (±3)/1cm, davon 8 Fäden PES FR & 5 Fäden PA und das folgende Untergewebe auf:
• Garn 100% PES FR, Bindung Tuch, Kettdichte 14 Fäden (±3)/1cm, Schussdichte 8 Fäden (±3)/1 cm

A particularly advantageous embodiment of the fabric has the following upper fabric:

• Yarn 80% PA, 20% PES FR, Atlas weave, weft exchange, warp density 27 threads PA (± 3) / 1cm, weft density 13 threads (± 3) / 1cm, of which 8 threads PES FR & 5 threads PA and the following lower fabric :
• Yarn 100% PES FR, cloth binding, warp density 14 threads (± 3) / 1cm, weft density 8 threads (± 3) / 1 cm

Uniform binding points are provided between the upper and lower fabric depending on the binding of the upper fabric. In the example given here, a PES FR yarn with a share of 20% is used in the outer fabric or fabric. Due to its construction, this yarn is not visible and has no or no significant contact with the test surface (Martindale). However, this proportion has a positive effect on the fire behavior.

List of reference symbols

1

Fabric (multi-layer fabric)

2

Upper fabric

3

Sub-fabric

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Non-patent literature cited

• DIN / EN / ISO 12947-2 [0008]

Claims (7)

Fabric (1), preferably for use in a motor vehicle, the fabric having an upper fabric (2) and a lower fabric (3) connected to it, the lower fabric (3) being a flame-retardant fabric. The fabric (1) according to Claim 1 , wherein the fabric is a flat fabric. The fabric (1) according to Claim 1 or 2 , wherein the outer fabric (2) comprises polyester (PES), polyamide (PA), wool, polyurethane (PU) and / or cellulosic fibers. The fabric (1) according to one of the Claim 1 to 3 , wherein the lower fabric (3) comprises or consists of FR PES. Seat cover consisting of or having a fabric (1) according to one of the preceding claims. Seat, preferably of a motor vehicle, with a fabric (1) according to one of the preceding claims. Method for producing a fabric (1) according to one of the preceding claims, wherein preferably a warp yarn of the upper fabric (2) and a warp yarn of the lower fabric (3) are fed simultaneously with independently controlled tension during weaving of the fabric (1).

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