JPH0255541B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a pile warp knitted fabric for automobile interior materials. More specifically, the present invention relates to a special pile knitted fabric knitted by a warp knitting machine suitable for car mats, door trims, etc. used as automobile interior materials.

[Conventional technology]

Conventionally, in the above-mentioned product field, tufted carpets produced by tufting machines have been the mainstream. However, since tufted carpet requires a primary base fabric, it is very heavy, has no stretch recovery properties as a fabric, and has difficulty in processing performance due to the snagging of tufted loops. A long pile structure could not be obtained, and it could not be said that the product had sufficient performance to satisfy consumers.

As a result of intensive studies to eliminate the drawbacks of conventional tufted carpet, the present inventor created a pile structure that eliminates the drawbacks of tufted carpet by creating a special pile structure using a warp knitting machine. The present invention was achieved based on the discovery that the present invention can be obtained.

On the other hand, it is known to produce pile fabric using a warp knitting machine. After knitting, the back side of the knitted fabric is raised to make it into a pile, or the amount of pile yarn supplied during knitting is increased to make it into a pile, or the ground yarn is not knitted with some knitting needles, so A pile fabric or the like has been devised in which a thin part extending in the vertical direction is formed in the ground knitted fabric, and the pile yarn is formed by forming loop piles at intervals of one course or more in the thin part of the ground knitted fabric.

[Problem to be solved by the invention]

Among these pile fabrics, raised pile fabrics have a very short pile length because the pile yarns that have already been organized are pulled out, and it is difficult to use thick pile yarns.
Pile fabrics formed by increasing the amount of pile yarn supplied during knitting and loosening the pile yarns have uneven pile heights and extremely low pile density, making them unsuitable for the automotive interior material targeted by the present invention. cannot be used for The ground yarn is not knitted by some of the knitting needles, thereby forming a thin section of the ground knitted fabric that extends in the vertical direction, and the pile yarn knits loop piles at intervals of one course or more in the thin section of the ground knitted fabric. Pile fabrics formed by opening are suitable for automobile interior materials, which is the object of the present invention, but conventionally these pile fabrics have been used as towels, gowns, and sportswear fabrics, and the pile yarns used are thin yarns. The coverage of the fabric surface by the loop pile was low, and the pile resilience required for automobile interior materials was lacking.

SUMMARY OF THE INVENTION An object of the present invention is to provide a pile warp knitted fabric for automobile interior materials that has loop piles of arbitrary length that can be knitted on a warp knitting machine without using special equipment.

[Means to solve the problem]

The pile warp knitted fabric for automobile interior materials according to the present invention is
A ground knitted fabric which is knitted by a warp knitting machine having a single row needle bed and has a thin portion extending in the vertical direction, and a pile yarn connected to the ground knitted fabric are separated at intervals of one course or more. A pile warp knitted fabric consisting of loop piles formed on a thin portion, where the product of the yarn weight per inch as the pile yarn and the gauge number of the warp knitting machine used is 3.2×10 ^-2 g・G or more. 11.9×
Using yarn satisfying the range of 10 ^-2 g/G, the pile yarn is connected to the ground knitted fabric by insertion, and the total pile yarn per square centimeter of pile warp knitted fabric is The length is in the range of 60 mm to 500 mm, and the number of piles per cm of pile warp knitted fabric is in the range of 3 to 10 in the vertical direction and 1.5 to 4 in the horizontal direction.
It is characterized by a range of .

In the warp knitted fabric having loop piles, natural fiber yarns, recycled fiber yarns, synthetic fiber yarns, or mixed yarns thereof can be used as pile yarns constituting the pile loops. As for the thickness of the pile yarn, as a result of intensive research by the present inventors, we found that in order to obtain the pile warp knitted fabric of the present invention, the thickness of the yarn per inch (g: grams) and the warp knitting machine used. Expressed as the product of gauge number (G: number of needles per inch), it is necessary to use the range from 3.2×10 ^-2 (unit: g・G) to 11.9×10 ⁻² (unit: g・G). I found out something. The reason why it is expressed as the product of the yarn weight per unit yarn length and the warp knitting machine's gauge number is because the appropriate pile yarn denier differs depending on the warp knitting machine's gauge number. Figure 1 shows the appropriate denier by gauge number. In Figure 1, the product of the yarn weight per inch and the warp knitting machine used is 2.1
The range from 10 ^-2 to 11.9×10 ^-2 is shown in region 2, and 3.2
The range from ×10 ⁻² to 11.9×10 ⁻² is shown in region 1. If the pile yarn is less than 3.2×10 ^-2 (unit: g・G), which is the product of the yarn weight per inch and the gauge number of the warp knitting machine, grooves between the piles will be noticeable in the direction of the knitted fabric course, and the pile will not stand up well. The surface of the knitted fabric cannot be covered by the pile loops, reducing its commercial value as a pile warp knitted fabric for automobile interior materials such as car mats and door trims. Also, if the product of yarn weight per inch and warp knitting machine gauge number is 11.9 x 10 ^-2 (unit: g/G) or more, it will be difficult for the pile yarn to escape from the warp knitting machine's needles, and the stand will stop during knitting. This leads to an increase in the number of knitted fabrics, which is disadvantageous in terms of cost, and the knitted fabric has the disadvantage that it has too much fabric weight.

In addition, the pile warp knitted fabric of the present invention has a total yarn length of pile yarns used per 1 square centimeter of knitted fabric.
It must be within the range of 60mm to 500mm, and the number of piles per centimeter of knitted fabric must be within the range of 3 to 10 in the horizontal direction and 1.5 to 4 in the vertical direction. be. The total yarn length of pile yarn used per square centimeter of knitted fabric is
60mm or less, the number of piles per centimeter of knitted fabric should be at least 10 in the course direction and 4 in the vertical direction.
Even if the loop pile is increased by more than 1, the loop pile is low and the surface of the knitted fabric cannot be covered with the pile yarn. The total length of the pile yarn is 60mm or less, and the number of piles per centimeter is 3 or less in the horizontal direction and 3 or less in the vertical direction.
If the number is less than 1.5, the knitted fabric will have mesh-like loose parts and lose its commercial value. In addition, if the total yarn length of the pile yarn is 500 mm or more and the number of piles is 3 or less in the horizontal direction and 11.5 or less in the vertical direction per centimeter, the coverage of the knitted fabric surface by the pile yarn will improve. The knitted fabric surface lacks resilience, which is essential for automotive interior materials such as car mats. If the total yarn length of the pile yarn is 500 mm or more and the number of piles per centimeter is 10 or more in the horizontal direction and 4 or more in the vertical direction, the resilience of the knitted fabric surface will improve, but the surface texture will be The disadvantage is that it becomes hard.

The present invention will be described in detail below with reference to the accompanying drawings.

FIG. 2 is a diagram showing the organization chart, threading state, and chain link combination of a pile warp knitted fabric in one embodiment of the present invention. The ground yarns 11 and 12 constituting the ground knitted fabric are passed through the reeds B ₁ and B ₂ in a half-set state, respectively, while the pile yarn 13 forming the loop pile is threaded into the reed B ₃ out of alignment with the ground yarn 12. In this state, thread the half set. For the sake of explanation, the knitting needles arranged in the first row of needle beds are alternately marked with symbols a and b.

Ground yarn 11 is fed to knitting needle a and is 2-1/1
- Repeat the wrapping of 2 to knit a chain link (the chain link shown on the right side of Figure 1 shows the case of 3 tempos). The ground yarn 12 is similarly supplied to knitting needles A, and 1-1/6-6 wrapping is repeated to perform insertion knitting (inlay knitting). The chain stitches formed by the ground yarns 11 are connected to each other by insertion stitches formed by the ground yarns 12 to form a ground knitted fabric.

In the first course, the pile yarn 13 is supplied to the knitting needles a for knitting the ground knitted fabric so as to perform insertion knitting. In this case, the pile yarn 13 is once jogged past the insertion folding position (wrapping position 3) to the wrapping position 1, and then returns to the folding position 3. After the pile yarn 13 returns to the wrapping position 3, the ground yarn 11 overlaps the knitting needle a, and at the same time the insertion reed _B3 swings idle. Thereafter, knitting needles a and b perform knockover.
Excessive shogging of the pile yarn 13 past the insertion and turn-back position as described above is to draw out excess pile yarn from the supply package of the pile yarn 13 to help form a loop pile. In the case described above, the pile yarn 13 is not connected to the ground yarn 11 between wrapping position 1 and wrapping position 3.

In the second course, the pile yarn 13 is fed to the knitting needles b that do not form a ground knitted fabric with overlap (6-5). In the third course, the pile yarn 13 is knitting needle a
and perform the insertion. At this time, it jogs beyond the other folding position (wrapping position 8) to wrapping position 9, returns to wrapping position 8, and idles at that position.
Thereafter, knitting needles a and b perform knockover. In this case, the pile yarn 13 supplied to knitting needle b in the second course is held in the hook of knitting needle b before the knockover, but in the third course, the pile yarn 13 is not supplied to knitting needle b. Therefore, the yarn 13 held by the hook of knitting needle b at the time of the knockover comes off from the hook, that is, comes off from knitting needle b, forming a loop pile 14.

In the fourth course, the pile yarn 13 is fed to the knitting needles b which do not form a ground knitted fabric with overlap (5-6). In the next fifth course, insertion knitting is performed in the same manner as in the first course. At this time, the yarn 13 supplied to the knitting needle b in the fourth course comes off from the knitting needle b and becomes a loop pile 14. The same knitting operation is repeated thereafter. As a result, loop pile 1 is created every other stitch and every other course including the second, fourth, sixth, and eighth courses.
4 is formed, and the pile yarn 13 is connected to the sinker loop of the ground knitted fabric by insertion knitting in the first, third, fifth, and seventh courses to obtain the pile warp knitted fabric of the present invention. It is.

Although FIG. 1 shows an example in which the loop pile 14 is formed every other stitch and every other course, this may be changed as appropriate depending on the desired pile form. For example, if the knitting needles that knit the ground knitted fabric are used every other to several courses, and the pile yarn is supplied to the knitting needles that knit the ground knitted fabric every two to several courses.
4 can be formed every one to several stitches and every two to several courses. Furthermore, as a method for knitting the pile yarn with the knitting needles used to knit the ground knitted fabric, insertion knitting is preferable because it can reduce the basis weight of the resulting pile warp knitted fabric. Furthermore, the ground knitting structure may be selected as appropriate, such as a chain knitting structure consisting of two reeds or a normal tricot structure.

The pile warp knitted fabric for automobile interior materials of the present invention has good dimensional stability because the ground knitted fabric performs the same function as the primary base fabric without using a primary base fabric like tufted carpet, and is extremely lightweight. It becomes a pile knitted fabric. In addition, since it is basically constructed entirely of a warp-knitted loop structure, it has excellent elongation recovery, which is a characteristic of knits, and has a flexible function when used in automobile interior materials that require three-dimensionality, such as car mats and door trims. The molding performance is greatly improved. In addition, since the pile is held within the loop of the knitted fabric, there is no possibility of the pile falling out due to external force. Therefore, the pile shedding phenomenon during the dyeing process is completely eliminated, and the productivity in the dyeing process is dramatically improved.

〔Example〕

Examples based on the present invention are described below.

Example 1 A warp knitting machine having a single row needle bed with a specification of 14 threads/inch was used, and ground yarns 11 and 12 knitted with knitting needles a were made of nylon 100 denier/24 in the same way as in Fig. 2. Nylon 1200 denier/64 filament yarn was used as pile yarn 13, which was knitted with knitting needle b, and was knitted in the following swing structure.

At this time, the product of the yarn weight per inch of the pile yarn 13 and the gauge number of the warp knitting machine (14G) is 4.7×10 ^-2
(Unit: g/G) The number of piles is 6 in the vertical direction and 3 in the horizontal direction per 1 cm of knitted fabric, and knitted so that the total yarn length of pile yarn per 1 square cm of knitted fabric is 180 mm. did. The resulting knitted fabric was dyed using a conventional method and had a basis weight of 340 g/m ²
It was a pile warp knitted fabric that was lightweight, the surface of the knitted fabric was covered with pile yarn, and had excellent surface resilience and a soft and graceful texture.

Ground thread 11 = 10/01 (1in/1out) Ground thread 12 = 00/55 (1in x 1out) Pile thread 13 = 22/54/77/45 (1out x 1in) Example 2 Has a single row needle bed Using a warp knitting machine with a specification of 18 yarns/inch, the ground yarns 11 and 12, which are knitted with knitting needles a in the same way as in Fig. 2, are made of polyester 75 denier/inch.
24 filament yarn was knitted using knitting needle b, using acrylic spun yarn 18/2 Nm yarn as pile yarn 13, with the swing structure shown below.

At this time, the product of the yarn weight per inch of the pile yarn 13 and the gauge number of the warp knitting machine (18G) is 5.0×10 ^-2
(Unit: g/G) The number of piles is 9 in the vertical direction and 3.5 in the horizontal direction per 1 cm of knitted fabric, and knitted so that the total yarn length of pile yarn per 1 square cm of knitted fabric is 410 mm. did. The obtained knitted fabric was spread out and dyed using a wince dyeing machine, and after being set at dry heat of 140° C. for 40 seconds, a polyethylene film was attached to the back side of the knitted fabric by a conventional method. The resulting pile warp knitted fabric had a basis weight of 510 g/m ² and a high density pile surface, and had a soft texture unique to acrylic yarn, making it an ideal warp knitted fabric for carpets.

Ground thread 11 = 01/10 (1in x 1out) Ground thread 12 = 77/00 (1in x 1out) Pile thread 13 = 32/55/23/00 (1out x 1in) Comparative example 1 - Knitting machine...24 pieces / inch ground yarn (11, 12)...Polyester 75 denier/24 filament/Warp structure...same as Example 2 Pile yarn 13...2/50Nm polyester spun yarn Number of piles...[9 in the vertical direction/ 5 pieces/1 cm in the horizontal direction of 1 cm] - A pile fabric was knitted with a total yarn length of pile yarn of 540 mm. At this time, the amount of yarn per inch of pile yarn and the gauge machine (24G) of the warp knitting machine
The product is 2.4×10 ^-2 (unit g・G). The obtained knitted fabric had a low coverage of the surface by the pile, so it was not possible to obtain an upright pile, and therefore the repulsion of the surface by the pile was almost non-existent. Moreover, the appearance resembled towel fabric at first glance, and was far from being an automobile interior material, which is the object of the present application.

Comparative example 2 - Knitting machine...18 pieces/inch - Ground yarn (11, 12)...polyester 75 denier/24 filament - Knitting structure...same as Example 2 - Pile yarn 13...300 ^d /60 polyester multifilament pile A pile knitted fabric was knitted with the number of stitches: 12 pieces in the vertical direction/1 cm, 4 pieces in the horizontal direction/1 cm, and the total yarn length of the pile threads: 580 mm. The product of yarn amount and gauge number at this time was 1.5×10 ^-2 g·G. This pile knitted fabric did not have upright piles, and therefore had poor surface resilience.

Comparative Example 3 A pile knitted fabric was knitted using a 28G knitting machine using a 150 ^d /30 f polyester multifilament as a pile yarn for use in magic tape. The product of yarn amount and gauge number of the obtained pile warp knitted fabric is 1.2, the total yarn length of the pile yarn is 770 mm, and the number of piles is 14 pieces/1 cm in the vertical direction and 5 pieces/1 in the horizontal direction.
It was centimeters.

〔Effect of the invention〕

Since the pile warp knitted fabric of the present invention is constructed as described above, it is a pile warp knitted fabric that uses relatively thick pile yarn compared to the gauge and has a pile length and pile density suitable for automobile interior materials. . Furthermore, compared to the tufted carpet that has conventionally been mainly used in this field, it is possible to reduce the weight by not using a base fabric and to obtain an excellent pile fabric with no snags in the pile threads.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing the usage area of the pile yarn constituting the pile warp knitted fabric of the present invention. Figure 2 shows
1 is a diagram showing a knitting organization diagram of a pile warp knitted fabric of the present invention. a, b...knitting needles, 1-8...course display, 11,1
2... Ground yarn, 13... Pile thread, 14... Loop pile.

Claims (1)

[Scope of Claims] 1. A ground knitted fabric which is knitted by a warp knitting machine having a single row needle bed and has a thin portion extending in the vertical direction, and a pile yarn connected to the ground knitted fabric with an interval of one course or more. In a pile warp knitted fabric consisting of loop piles that are opened and formed on the thin part of the ground knitted fabric, the product of the yarn weight per inch of the pile yarn and the gauge number of the warp knitting machine used is 3.2 ×
Using yarn satisfying the range of 10 ^-2 g・G to 11.9×10 ⁻² g・G, the pile yarn is connected to the ground knitted fabric by insertion, and 1 square centimeter of the pile warp knitted fabric The total yarn length of the pile yarn per unit starts from 60 mm.
A pile for automobile interior materials, which is within the range of 500 mm, and the number of piles per cm of pile warp knitted fabric is in the range of 3 to 10 in the vertical direction and in the range of 1.5 to 4 in the horizontal direction. Warp knitted fabric.