JP2006348455A - Sheet material for motor vehicle or the like - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sheet material for motor vehicles or the like, freed from laminated structure with conventional polyurethane foam or the like, thus being of integrated structure with excellent cushionability, springiness and fabric property. <P>SOLUTION: The sheet material consists of a knitted fabric structure composed of knitted fabrics 1 and 2 comprising a number of parallel stitch rows extending longitudinally in respective obverse and reverse rows at necessary spacings inbetween and a number of joining yarns that join both kinds of the stitch rows in between the obverse and reverse knitted fabrics. In this sheet material, stitch profile or the like constituting the obverse side knitted fabrics is limited, and needle loop shape is deformed through combining reed motion attributable to the joining yarns with the outside design of the obverse side knitted fabrics to uniformize surface raised fluffs 6 to afford fabric property, and as necessary, a number of wefts 4 are orthogonally inserted into the reverse side knitted fabrics 2 to afford springiness, and also, as the joining yarns, high-strength monofilaments of high elastic recovery tendency are used to afford improved fashionability. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a seat material used for seats for vehicles such as automobiles and trains, reception chairs, and the like, and in particular, cushioning and fashion without using polyurethane foam which has been conventionally used for providing cushioning. This is related to a seat material with excellent spring and spring properties.

Conventionally, seat materials such as seats for automobiles and trains, as well as seat materials for various chairs, are centered on woven moquette fabrics, ordinary woven fabrics, brushed fabrics and warp knitted fabrics partly knitted using double raschel machines. Cut and raised warp knitted fabrics have been used, but these usually have a thin thickness and lack cushioning properties, so a foam material such as polyurethane foam is bonded to the surface with fabric and the back material is bonded to the back. Was common. In particular, in the case of warp knitted fabrics, the strength is inferior, and the thickness of the fabric is limited. However, the laminated polyurethane foam as described above has environmental problems such as generation of toxic gas upon disposal incineration. Therefore, it has been proposed to produce a sheet material having a three-layer structure with a double-sided circular knitted fabric without using polyurethane foam. (For example, see Patent Document 1)
This sheet material is formed with a three-layer structure having a surface yarn, a lining yarn, and a connecting yarn that connects the surface yarn and the lining yarn, and the connecting yarn is tucked alternately inside the knit stitch of the surface yarn and the lining yarn. Although the knitted fabric is connected so as to have a hexagonal shape, improvement of the device surface such as a knitting needle hook shape and a cam shape is required, which is difficult in production.

Therefore, recently, a double raschel knitted fabric is made as a vehicle seat material, and it is composed of a surface fabric, a back fabric, and a connecting yarn that forms a gap between the two fabrics, and the surface of the surface fabric is raised. In a double-layer warp knitted fabric having a four-layer structure double raschel three-dimensional knitted fabric (see, for example, Patent Document 2), two opposing base fabrics, and a connecting yarn formed by connecting and knitting the base fabric. One base fabric is composed of a combination of at least two types of ground yarns, and the overlap direction of the other ground yarns except for one type of ground yarn and the overlap of the ground yarns and the connecting yarns are removed. A double raschel knitting has been proposed in which the knitting is performed in the reverse direction, with other ground yarn set to overfeed, and the ground yarn bulging outward to raise the surface (see, for example, Patent Document 3). .
JP 2001-214346 A Japanese Patent Laid-Open No. 10-325056 Japanese Patent No. 3136342

  However, among the above-mentioned proposals, the surface raised four-layer structure double raschel solid knitted fabric and the two kinds of ground yarn constituting one base fabric overlap the inner ground yarn and the connecting yarn with the outer ground yarn. Although the direction is reversed and the outer ground yarn is overfeeded and the needle loop of the yarn bulges outward, it has an excellent surface in terms of cushioning, breathability, etc. In addition to being inferior in the expressiveness of the material feeling, which is an inherent characteristic of the material, the raised bulge is uneven, and the appearance and feel of the sheet are difficult.

  The present invention addresses the actual situation as described above, uses an existing double raschel machine, changes the knitting structure, combines the yarn material, the amount of yarn, etc., and changes the needle loop shape from the conventional shape, It is an object of the present invention to provide a sheet material for a vehicle or the like that has a uniform raised surface as a sheet material and has an excellent appearance and tactile sensation that are inherent to the sheet material.

 That is, the invention according to claim 1 suitable for the above-mentioned object is a double raschel three-dimensional knitted fabric comprising a front side knitted fabric, a back side knitted fabric, and a connecting yarn that connects both the knitted fabrics by forming a gap. The surface side knitted fabric is formed with an underlap of two stitches or more at the outermost knitting structure, and the inner knitting structure is swung by one stitch or more with respect to the outer knitting structure. Reverse and underlap are formed in the reverse direction, and the stripe structure of the inner connecting yarn is swung over the outermost knitted structure by two stitches or more, and the overlap is reversed and the underlap is formed in the same direction. In addition, a high-strength synthetic monofilament excellent in elastic recovery is used for the yarn connecting the front and back knitted fabrics, and the surface side knitted fabric is raised.

  The invention according to claim 2 is characterized in that a large number of wefts are inserted into the stitch row of the knitted fabric on the back surface side so as to be orthogonal to the stitch row.

  The invention according to claim 3 is characterized in that the connecting yarn is one monofilament selected from polyamide, polyterimethylene terephthalate, and polyester monofilaments.

  The invention according to claim 4 is characterized in that the thickness of the sheet is 3 to 10 mm, preferably 5 to 8 mm.

  According to the first aspect of the present invention, the surface side is peeled off from the conventional needle loop shape, and the surface side has the appearance and feel that the skin material originally has, the raised hair is uniform and beautiful, and the elastic recovery is excellent. In addition to the use of a connecting thread with increased strength, it has excellent cushioning properties and spring properties, and has the effect of being useful as a sheet material under environmental management without using a foamed polyurethane foam.

  Also, combining the connecting yarns, swinging the outermost tissue over 2 stitches, the overlap is reversed and the underlap is the same direction, that is, the direction of the underlap is to deform the needle loop of the ground yarn , And the amount of thread balance, it is deformed by the action of a directional movement to the left and right, thereby removing the conventional needle loop shape, so-called “knitted shirting” tone, and being a sufficient appearance as a skin material , You can get a feel.

  According to the invention described in claim 2, since a large number of wefts are inserted in the stitch row of the knitted fabric on the back surface side so as to be orthogonal to the stitch row, the spring property is excellent, and the foamed polyurethane foam is It has the effect of being useful as a sheet material under environmental management without being used.

  According to the invention described in claim 3, since the connecting yarn is one monofilament selected from the monofilaments of polyamide, polyterimethylene terephthalate and polyester, it is excellent in elastic recovery and enhances fashionability. it can.

  According to the invention described in claim 4, since the thickness of the seat is 3 to 10 mm, preferably 5 to 8 mm, the cushioning property is excellent, and a sense of incongruity when sitting is not generated.

  Using an existing double raschel machine, the needle loop shape is transformed from the conventional shape by limiting the knitting structure and combining the yarn material, yarn amount, etc. In order to provide a sheet material for a vehicle or the like, which is a three-dimensional knitted fabric having a certain excellent appearance and touch, a double raschel comprising a front side knitted fabric, a back side knitted fabric, and a connecting yarn that connects both knitted fabrics with a gap formed therebetween. The surface knitted fabric is a three-dimensional knitted fabric, and the outermost knitted structure is formed with an underlap of two stitches or more with an open stitch, and the inner knitted structure is one stitch with respect to the outer knitted structure. The overlap is reversed and the underlap is formed in the reverse direction when the swing is over. Further, the stripe structure of the inner connecting yarn is swung over two stitches with respect to the outermost knitted structure, and the overlap is reversed and the underlap. In the same direction Together is made, the yarn connecting the front and back knitted fabrics are used is superior strength Univ become synthetic monofilament elastic recovery, and on the surface side knitted fabric by becoming is decorated brushed, was realized.

  1 to 4 are diagrams showing an embodiment of the present invention.

  FIG. 1 is a front view showing a part of a sheet material according to this embodiment, FIG. 2 is an enlarged cross-sectional view thereof, and reference numerals 1 and 2 in FIGS. Each of the front and back knitted fabrics is formed by a stitch row 3 that is knitted and extended in the length direction. The raised knitted fabric 6 is applied to the front side knitted fabric, while the back side knitted fabric 3 is an example thereof. A weft 4 is appropriately inserted in a substantially orthogonal direction. Reference numeral 5 denotes a connecting yarn that alternately zigzags between the mutually opposing loops between the opposing stitch rows 3 in the front and back knitted fabrics 1 and 2 to connect the front and back stitch rows 3. In the sheet material of this embodiment, the knitting of the stitch row 3, the insertion of the weft yarn 4 and the connection by the connecting yarn 5 are performed using the double raschel machine with a weft insertion device shown in FIG. A three-layered knitted structure of a front yarn layer, a back yarn layer, and a connecting yarn layer integrally formed by movement is formed.

  That is, in the double raschel machine, the front and back stitch rows are formed by the collars L1 and L2 that form the front side F (front side) needle series and the collars L5 and L6 that form the back side B (back side) needle series. When necessary, wefts are inserted on the back side as necessary to form front and back knitted fabrics, while the front and back knitting rows are appropriately opposed to each other at zigzag positions by the ribs L3 and L4. By connecting and connecting the stitch rows with connecting yarns, the three-layered integrated fabric structure is obtained.

  This structure has a three-axis structure composed of planar knitted fabrics 1 and 2 in the XY axis direction and connecting yarns 5 in the Z-axis direction for connecting the knitted fabrics 1 and 2, and has a three-dimensional structure. The knitted fabric has an advantage that the thickness, width, and length between the knitted fabrics can be appropriately adjusted depending on the knitting condition, and can be arbitrarily controlled.

  Thus, the sheet material of this example is characterized in that, in the formation of the knitted fabric structure by the double raschel machine, the knitting structure is particularly limited, and the nappings raised on the surface side are made uniform. is there.

  FIG. 4 shows an example of a structure knitted by the double raschel machine. In the double needle row warp knitting machine, the surface side knitted fabric 1 is formed by the ridges L1 and L2 in FIG. Thus, the back side knitted fabric 2 is formed, and the three-dimensional knitted fabric is constituted by the connecting yarns 5 of the ribs L3 and L4 that connect the front and back knitted fabrics.

  In the knitting structure of the heels L1, L2 and the connecting thread ridges L3, L4 constituting the surface side knitted fabric, as shown in FIG. 4, the knitting structure of the heel L1 is formed by an underlap of two or more needle swings. The opening of the needle swing.

  Next, as shown in FIG. 4, the knitting structure of the heel L2 is a single stitch or more with respect to the knitting structure of the heel L1, and the overlap is reverse and the underlap is the reverse direction.

  Here, the point of this embodiment is the movement of the connecting yarns L3 and L4 with respect to the combination of the knitting structures of the above-described hooks L1 and L2.

  That is, the movement in the knitting structure of the heels L3 and L4 is, as an example shown in FIG. It has become. And the movement needs to be limited also with respect to 筬 L2, the movement of 筬 L3, L4 is two or more needles with respect to 筬 L2, and it is perpendicular to the overlap of 筬 L2, and the underlap direction is The organization is in the opposite direction. As a result, the yarn to be raised on the surface side is ensured uniformly, and uniform raising can be achieved.

  The back side knitted fabric 2 employs the basic knitting structure of the above-mentioned front side knitted fabric 1 with the ridges L1 and L2. However, when the processing such as raising is performed, the invention is not limited to the above knitting structure. Any material that satisfies the knitted fabric can be used and is not limited.

  In the knitted fabric, the yarn material used for the knitted fabrics 1 and 2 on the front surface side and the back surface side, and the yarn material used for the insertion weft yarn 4 and the connecting yarn 5 can be appropriately selected. , Aramid, polyester, polyacrylic synthetic fiber, etc. can be used, and polyester yarn is generally preferred as the knitting yarn for the front and back. However, as the connecting yarn, a yarn having strength and excellent elastic recovery is suitable.

  Examples of this type of yarn include aromatic polyamide and polyterimethylene terephthalate monofilament yarn. The stitch forming yarns and weft yarns are not limited to monofilament yarns but may be multifilament yarns. However, multifilament yarns and converging yarns are advantageous for subsequent surface raising and reduce deterioration of the knitting ground. Monofilaments, multifilaments or converging yarns can also be used as the connecting yarns. However, the use of monofilaments is effective in terms of the elastic recovery function and strength, and the concatenating yarn layers are particularly converging with as many monofilaments as possible. Forming is effective in enhancing cushioning and springiness. The thickness of each of these yarns is not particularly large or thin, but in order to form a brushed appearance on the surface in order to improve fabricability as a sheet material, a thickness suitable for this is appropriate, and usually 120 About 200 denier, preferably about 150 denier is used.

Further, in forming the knitted fabric, in particular, in order to raise the surface side stitches by the outermost ridge L1 as described above, the tension is set to the lowest possible tension, and the yarn amount of the knitted fabric is reduced under no tension. preferably to make a large amount used relative to the normal of the fabric, therefore, the 1000 g / m ² or more basis weight, preferably preferably set to 1250 g / m ² approximately. However, the weight of two surface raised surfaces is about 300 g / m ² , and usually about 150 g / m ² .

  Furthermore, a large amount of yarn used for connecting yarns is effective in improving the compression elasticity recovery as a structure and improving the cushioning and spring properties, but it is not necessary to increase the amount in particular. . In this case, as described above, the thickness of the sheet material is preferably 3 to 10 mm, particularly about 5 to 8 mm.

  Here, the amount of yarn is the amount of yarn per unit and is not necessarily limited to the number of yarns, but the weight of the yarn per unit is also conceivable, but there is a relationship with the thickness of the yarn, and the sheet material as a whole Needless to say, a thread thickness, basis weight, and thread density suitable for each are selected.

  The seat material described in the above embodiment is suitable mainly for use in vehicles such as automobiles and trains, but it can also be used as a seat sheet material including a chair in a home or a cheering set in a building.

It is a perspective schematic diagram which shows a part of sheet material which concerns on one Example of this invention. It is sectional drawing of the sheet | seat material of FIG. It is a knitting part schematic diagram of a double raschel warp knitting machine for knitting a knitted fabric according to one embodiment of the present invention. It is a figure which shows the wrapping state of each heel in the knitted fabric which concerns on one Example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Surface side knitted fabric 2 Back surface side knitted fabric 3 Stealing line 4 Weft 5 Connection yarn 6 Raised

Claims (4)

A double raschel three-dimensional knitted fabric composed of a connecting yarn that connects the front side knitted fabric, the back side knitted fabric and both knitted fabrics by forming a gap,
The surface side knitted fabric is formed with an underlap of two stitches or more at the outermost knitting structure, and the inner knitting structure is one stitch or more with respect to the outer knitting structure and the overlap is reversed. The underlap is formed in the opposite direction, and the stripe structure of the inner connecting yarn is swung over the outermost knitted structure by two stitches or more, the overlap is reversed, and the underlap is formed in the same direction. In addition, a sheet material for a vehicle or the like, wherein a synthetic monofilament having high strength excellent in elastic recovery is used for the yarn connecting the front and back knitted fabrics, and the surface side knitted fabric is raised.   2. A sheet material for a vehicle or the like according to claim 1, wherein a number of wefts are inserted into the stitch row of the knitted fabric on the back side so as to be orthogonal to the stitch row.   The sheet material for a vehicle or the like according to claim 1 or 2, wherein the connecting yarn is one monofilament selected from polyamide, polyterimethylene terephthalate, and polyester monofilaments. The sheet material for a vehicle or the like according to any one of claims 1 to 3, wherein the thickness of the sheet is 3 to 10 mm, preferably 5 to 8 mm.

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