KR20090034605A - Environmental seat fabric and a method of fabricating the same - Google Patents

Abstract

Environmental seat fabric and a method of manufacturing the same are provided to offer cushion property and comfort and to increase air permeability by making solid structure. A method for manufacturing environmental seat fabric comprises the following steps of: organizing a surface layer and a back layer with the same material(S100); completing fabric of the back layer by using a moquette or a circular knit, and double raschel method to make a cushion property(S200); and connecting a yarn in the surface layer with the woven back layer(S300). A raw material of the yarn is one selected from polyester, polyethylene, polyamide, and polyacryl.

Description

Eco-friendly sheet fabric and manufacturing method thereof {Environmental seat fabric and a method of fabricating the same}

The present invention relates to a sheet fabric and a manufacturing method thereof, and in particular, to provide an eco-friendly sheet fabric and a method of manufacturing the raw material can be recycled, the productivity is improved, the cushioning and comfort can also be exhibited with the breathability of the sheet.

Recently, with the rise of environmental issues throughout the industry, the importance of recycling, waste containment, and resource preservation are increasing. Therefore, in order to effectively reuse waste parts and recycle wastes in industrial products, dismantling of waste products has emerged as the most important factor, and one of the alternatives is to make the raw materials of the products consist of a single material.

1 is a structural diagram of an existing sheet. Referring to FIG. 1, in order to provide cushioning property in a vehicle, a conventional general sheet includes a skin layer 10, an intermediate layer 20, a back layer 30, and a three-layer structure. The skin layer 10 and the back layer 30 of the fabric is used polyester, nylon, polypropylene, acrylic, etc., the intermediate layer 20 is a polyurethane foam is used. In order to combine the fabric, the intermediate layer 20 melts the surface of the polyurethane foam with fire to produce a sheet fabric by combining the fabric of the front and back surfaces. Therefore, the above structure is difficult to recycle since it is not easy to separate after bonding other raw materials in each layer. In addition, in the lamination process, flame lamination is used on both sides of the polyurethane foam, in which the pollutants generated by melting the polyurethane foam and the remaining organic chemicals in the polyurethane foam are sealed at a high temperature. Volatilization in the use environment causes fogging problems that adhere to and blur the glass. In addition, harmful emissions of cyan gas and pollutant emissions from the manufacturing process are released into the atmosphere, causing environmental pollution, and its use is increasingly restricted. Factors should be replaced by methods that are effective in eliminating hazards and using environmentally friendly materials. In addition, the polyurethane foam of the intermediate layer is composed of a closed type, there is no air permeation, when the moisture is filled with microorganisms can be unsanitary.

In order to solve this problem, U.S. Patent No.5747393 arranges polyester / polyester copolymer or viscose rayon spunbond nonwoven fibers in the form of a sandwich of four layers instead of polyurethane foam in the intermediate layer 30 to impart air permeability and cushioning properties. Sheet fabrics have been proposed that are shown and recycled. However, there are disadvantages in that the process hassle for forming a multi-layered arrangement and excellent cushioning properties such as foams are not expressed.

In addition, Korean Patent Laid-Open Publication No. 2003-72831 relates to a composite sheet for automobile interior materials manufactured by thermal compression molding of bamboo fibers and polypropylene fibers, and a method of manufacturing the same, including polypropylene fibers (60 to 40%) and bamboo fibers ( 40 to 60%) using a mixing machine for the complete mixing; Evenly spreading the mixed raw materials with a carding machine; Forming an evenly spread raw material into a uniform thickness using a forming machine; processing the raw material formed into a uniform thickness with a needle punching machine as a nonwoven felt; cutting the processed nonwoven felt to a certain standard; and It is characterized by consisting of the step of forming a sheet shape by hot pressing the cut fabric at a temperature of 50 to 70kg / ㎠ at a temperature of 150 ℃ to 200 ℃ and the step of completing a cold-pressed pressing the pressed sheet A method of manufacturing a composite sheet for automotive interior materials has been proposed. However, the composite sheet is a mixture of bamboo and resin is not possible to recycle to a single fiber, due to the characteristics of the bamboo lacks cushioning and comfort.

In order to solve the above problems, an object of the present invention consists of two layers or a single layer of the fabric of the surface layer and the back layer to improve the productivity by simplifying the manufacturing process, it is hygienic by increasing the air permeability by forming a three-dimensional structure, To provide a cushioning and comfortable sheet fabric and a method of manufacturing the same.

In addition, the present invention is to provide a manufacturing method that is environmentally friendly by using a combined method that can be recycled by using a single raw material for both layers of the fabric, the emission of pollutant is reduced.

In order to achieve the above object, the present invention, in the eco-friendly sheet fabric, the fabric of the skin layer and the back layer includes a two-layer structure or a single layer structure of only the back layer, the back layer is made of a surface layer, an intermediate layer, a bottom layer It provides an eco-friendly sheet fabric characterized in that.

In addition, the present invention is an eco-friendly sheet fabric, characterized in that the raw material of the skin layer and the back layer is selected from the same raw material of the two layers in the polyolefin-based, polyamide-based, polyacrylic, such as polyester, polyethylene, polypropylene To provide.

In addition, the present invention provides an eco-friendly sheet fabric, characterized in that the thickness of the yarn used in the intermediate layer in the back layer is 10 to 100 denier, the thickness of the yarn used in the surface layer and the bottom layer is 20 to 200 denier. .

In addition, the present invention provides a mesh-type eco-friendly sheet fabric made of the back layer is woven in a double-lasel type.

In addition, the present invention in the manufacturing method of the eco-friendly sheet fabric, yarn composition step of configuring the skin layer and the back layer with the same material; A weaving step of completing the fabric of the backing layer using a double laselle, a moquette or a circular knitting method to provide cushioning properties with the yarn constructed above; It provides a manufacturing method of the eco-friendly sheet manufactured through the step of combining the yarns of the back layer and the skin layer woven in the above method.

In addition, the present invention, in the yarn composition step of the outer skin layer and the back layer, the raw material of the yarn is selected from the same raw material of the two layers in the polyester, polyethylene, polyolefin-based such as polypropylene, polyamide-based, polyacryl-based It provides a method for manufacturing an eco-friendly sheet fabric, characterized in that made.

In addition, the present invention in the yarn configuration step, the thickness of the yarn used in the intermediate layer constituting the back layer is 10 to 100 denier (Denier; de), the thickness of the yarn used for the surface layer and the bottom layer 20 to 200 It provides a manufacturing method of eco-friendly sheet fabric, characterized in that the denier.

In addition, the present invention provides a manufacturing method of the eco-friendly sheet fabric, characterized in that in the weaving step, the back layer is made of a mesh structure.

In addition, the present invention provides a manufacturing method of the eco-friendly sheet fabric, characterized in that in the step of bonding, the adhesive resin is bonded in the form of hot melt, solid content, water-soluble adhesive.

In addition, the present invention provides a method for producing an eco-friendly sheet fabric, characterized in that the adhesive resin is at least one selected from the group consisting of polyester, polyethylene, polyolefin, such as polypropylene, polyamide, polyacrylic, polyurethane-based. .

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. First of all, it should be noted that in the drawings, the same components or parts denote the same reference numerals as much as possible. In describing the present invention, detailed descriptions of related well-known functions or configurations are omitted in order not to obscure the subject matter of the present invention.

As used herein, the terms "about", "substantially", and the like, are used at, or in close proximity to, numerical values as are indicative of preparation and material tolerances inherent in the meanings mentioned, and are intended to be accurate or to facilitate understanding of the invention. Absolute figures are used to prevent unfair use by unscrupulous infringers.

Hereinafter, the present invention will be described as an example of a car seat, but is not limited thereto.

The term "fabric" specified in the present invention is used to include all articles, nonwoven fabrics, and fibrous webs produced by weaving or knitting.

Further, in the present invention, the seat is a cushioning material for seats, such as automobiles, railroad cars, aircrafts, children's seats, baby cars, offices, bedding, mattresses, pillows, cushions, cushions, medical spacers, implants, cushioning materials, etc. Or the like.

Figure 2 shows the structure of the sheet according to an embodiment of the present invention. 2, the sheet according to the preferred embodiment of the present invention is a two-layer structure consisting of a skin layer 100 and a back layer 200.

The skin layer 100 is a flat fabric having a planar structure, the back layer 200 may be made of a fabric having a three-dimensional structure to exert air permeability. The skin and backing layer fabric of the polyester and polyethylene, polypropylene, such as polypropylene, polyamide-based, polyacryl-based fibers may be selected from the one-piece material consisting of 100% yarn.

Figure 3 shows a detailed structural diagram of the sheet according to an embodiment of the present invention. Referring to FIG. 3, in the detailed structure according to the exemplary embodiment of the present invention, the back layer 200 may be formed of the surface layer 210, the intermediate layer 220, and the bottom layer 230 in detail below the skin layer 100.

The surface layer 210 may be used as a skin layer of the entire sheet without a skin layer 100 by forming a design. Therefore, the sheet may be composed of a single layer structure consisting of the back layer 200.

The intermediate layer 220 included in the back layer 200 is preferably 10 to 100 denier mono yarns for imparting cushioning properties. When the thickness of the yarn is less than 10 denier, the recovery of elasticity is slow and the cushioning feeling is slow, and when it exceeds 100 denier, it is difficult to exert cushioning and a comfortable feeling. In addition, since the surface layer 210 and the bottom layer 230 supports the shape of the fabric, it is preferable to use 20 to 200 denier yarns. If the thickness of the yarn is less than 20 denier, the supportability of the surface layer is low, and the shape of the fabric is easy to be deformed when the entire fabric is completed, and if it exceeds 200 denier, the touch of the sheet is rough and the comfort is insufficient. .

The back layer may be manufactured using a double raschel, a moqqette or a circular knit machine to form a three-dimensional solid structure. Preferably, the mesh fabric is produced using a double raschel machine. The mesh fabric is a fabric that provides cushioning and comfort with a highly breathable three-dimensional structure, and is mainly woven by a double laselle machine, and is a double laselle 3D mesh fabric, a DNB 3D mesh fabric, and a DNB spacer fabric. Also called.

Figure 4 shows the manufacturing method of the mesh fabric by the double lassell method according to an embodiment of the present invention. In the above method, a three-layer fabric having cushioning properties is manufactured using a double-lasel machine having two needle bars. 4, 1 to 6 are guides, and 7 and 8 are needle bars, ie needles. In the manufacturing method, the yarns derived from the 1,2 guides form the surface of the surface layer 210 by the fibrous structure (a), and the yarns derived from the 5 and 6 guides form the back surface of the bottom layer 230 (c). The yarns guided by the 3 and 4 guides are sewn (b, d) reciprocally on both needles of the surface and the bottom to form an intermediate layer 220 of the form (e) connecting the surface layer 210 and the bottom layer 230. In general, according to the model, the double laselle facility has 4 to 8 guides, and the guide method of the thread forming the bottom, the surface, and the intermediate layer may vary depending on the number of guides.

Figure 5 shows a method for producing a sheet according to an embodiment of the present invention. Referring to Figure 5, the manufacturing method according to an embodiment of the present invention may proceed to the yarn configuration step S100, weaving step S200, happo step S300. Detailed description of the above steps, the yarn composition step S100 to configure the skin layer and the back layer of the same material, to provide cushioning with the configured yarn, Double Raschel, Moqqette or Circular Knit The sheet may be manufactured through a weaving step S200 for completing the fabric of the back layer using a machine, and a step S300 for connecting the yarns of the woven intermediate layer and the surface layer.

Referring to the combined step S300, the fabric is processed using hot melt bonding in connecting the surface layer and the back layer. The hot melt raw material used herein melts the adhesive resin using heat without using a solvent, and then bonds the fabric by using a hardening property to cool down to complete the sheet fabric. The adhesive resin may be bonded in the manner of a multi-roller, a slot die, and a skater in the form of a hot melt, a solid component, and a water-soluble adhesive. In addition, the adhesive resin may include polyester, polyethylene, polyolefin-based, polyamide-based, polyacryl-based, polyurethane-based, such as polypropylene. The resin is in the form of powder or particles. Since the adhesive method does not use a solvent, there is little leakage of pollution or harmful substances to the human body, and the adhesive effect can be obtained quickly. In addition, strong adhesion can be maintained, and can be used in bookbinding, wood, and packaging industries in addition to fabrics.

Figure 6 shows an image of a sheet fabric according to a preferred embodiment of the present invention. The above-described manufacturing method is a sheet fabric manufactured by combining the skin layer 100 made of polyethylene terephthalate filament yarn with the back layer 200 woven into the mesh structure of the surface layer 210, the middle layer 220, and the bottom layer 230 by a double laselle machine using the same raw material.

As described above, the sheet of the present invention consists of a two-layer structure of the epidermal layer and the back layer, thereby simplifying the process to improve productivity. There is an effect that is given.

In addition, both the surface layer and the back layer of the sheet can be recycled using a single raw material, and an environmentally friendly manufacturing method is provided by using a composite method in which pollution is reduced, thereby reducing environmental pollution.

In addition, in the back layer, a design may be formed on the front layer to form a sheet having a single layer structure with only the back layer having three-dimensional properties without a skin layer.

It will be described in more detail through the following examples.

Example  One

Yarn composition stage

Both the skin layer 100 and the back layer 200 were made of polyethylene terephthalate filament yarn, and the middle layer 220 was made of polyester mono yarn.

(Section Preparation Stage-Canon)

Each yarn to be used for the surface layer, the middle layer, and the back layer was wound by setting the length of the yarn required by equal tension to a predetermined beam with the normal number of heads required by the design.

(Assembly stage)

22 Gauge Double Needle Bar Raschel Knitting Machine with 6 Guide Bars at 3mm Bed Gap (Between). Each beam is composed of L1,2 for the surface layer, intermediate layer and back layer. bar, the middle layer is the L3 bar, which can play a role of connecting the surface and the back side, the back layer is located in the L5,6 bar position.

Each yarn is passed through the tension bar according to each yarn path to be discharged from the cannon beam, and then through each guide, and then through the movement motion of each guide bar by the organization specified below at the proper delivery rate of each guide bar. The loops are formed by the needles, in which the surface layer and the back layer are connected to each other by yarn of the intermediate layer, and the spacer dough is cut to a density of 30 courses / 2.54 cm.

The obtained dough was heat-heat-set in a tent at 170 ° C. for 1 minute, and a spacer having a three-layer structure in which the surface was reduced by 11% of the width of the dough (63 inches) and the back surface was connected by an intermediate layer ( Mesh) fabric.

<Organization Chart>

1: 1011/2322

2: 1211/1011

3: 1012/2321

5: 1112/1110

6: 1110/2223

(Synthesis phase)

The fabric of the skin layer 100 and the back layer 200 obtained above was combined by the following method using a CAVIFLEX (manufactured by Cavitex) equipment to produce a final sheet fabric.

Supply the fabric of the skin layer 100 to 23 mesh gravure roller or mesh roller to dot print the polyolefin adhesive having 100% solids on the skin fabric, and then the fabric of the back layer 200 without adhesive to the pressure roller. The adhesive is pressed with the fabric of the epidermal layer 100 on which the adhesive is dot-printed to fabricate the fabric. In the printing method of the adhesive, the adhesive in the solid state was heated to 110 ° C. to be in a liquid state and transferred to a hot melt supply bath using a suction bath. This is a method in which the adhesive contained in the hot melt supply tank is coated on the surface of the roller and printed on the fabric. The feeder should be supplied with 100 ° C heat so that the adhesive does not stick to the state of the liquid.

The laminated fabric is such that the skin layer 100 and the back layer 200 is not peeled off.

After leaving for 24 hours in a aging room supplied with a temperature of 25 ° C. and a humidity of 70%, the surface layer 100 and the back layer 200 were fixed so as not to be separated, and then a sheet suitable for physical properties of the vehicle was manufactured through inspection.

The cushioning property of the sheet original fabric obtained by said method is shown below.

Test Methods

* Cushioning (elasticity)

Example 1 The sheet produced by the method is placed on a table, and lightly pressed three times with the fingertips (three fingers) from the top to sense the elasticity according to the following criteria. Evaluate before and after repeated compression.

◎: high elasticity, ○: slightly high elasticity

(Triangle | delta): A feeling of elasticity is low, X: There is almost no sense of elasticity

division Elasticity Example 1 ◎

As a result of Table 1, the sheet produced by the method according to Example 1 exhibited satisfactory cushioning properties.

The present invention described above is not limited to the above-described embodiment and the accompanying drawings, and various substitutions, modifications, and changes are possible within the scope without departing from the technical spirit of the present invention. It will be evident to those who have knowledge of.

1 is a structural diagram of an existing sheet.

2 is a structural diagram of a sheet according to an embodiment of the present invention.

Figure 3 is a detailed structural diagram of a sheet according to an embodiment of the present invention.

Figure 4 is a manufacturing method of the mesh fabric by the double lassell method according to an embodiment of the present invention.

5 is a manufacturing method of the sheet according to an embodiment of the present invention.

Figure 6 is an image of a sheet fabric according to a preferred embodiment of the present invention.

<Description of Major Symbols in Drawing>

1 to 6: Guide 7, 8: Needle bar

10: epidermal layer 20: intermediate layer 30: back layer

100: epidermal layer 200: back layer

210: surface layer 220: intermediate layer 230: bottom layer

S100: Yarn forming step S200: Weaving step S300: Lapping step

Claims (10)

Eco-friendly sheet fabric, Eco-friendly sheet fabric, characterized in that the fabric of the skin layer and the back layer includes a two-layer structure or a single layer structure of only the back layer, wherein the back layer is made of a surface layer, an intermediate layer, and a bottom layer. The method of claim 1, Eco-friendly sheet fabric, characterized in that the raw material of the skin layer and the back layer is selected from the same material of the two layers in the polyester, polyethylene, polyolefin-like, polyamide-based, polyacrylic, such as polypropylene. The method of claim 1, Eco-friendly sheet fabric, characterized in that the thickness of the yarn used in the intermediate layer in the back layer is 10 to 100 denier, the thickness of the yarn used in the surface layer and the bottom layer is 20 to 200 denier. The method of claim 1, The back layer is a mesh-friendly eco-friendly sheet fabric made of a double-lassel method. In the manufacturing method of eco-friendly sheet fabric, Yarn composition step of constructing the skin layer and the back layer of the same material; A weaving step of completing the fabric of the backing layer using a double laselle, a moquette or a circular knitting method to provide cushioning properties with the yarn constructed above; The method of manufacturing an eco-friendly sheet manufactured through a step of combining the yarns of the back layer and the skin layer woven in the above method. The method of claim 5, In the yarn construction step of the skin layer and the back layer, A method of manufacturing an eco-friendly sheet fabric, characterized in that the raw material of the yarn is selected from the same raw material for both layers of polyolefin-based, polyamide-based, and polyacryl-based such as polyester, polyethylene, and polypropylene. The method of claim 5, In the yarn forming step, The thickness of the yarn used for the intermediate layer constituting the back layer is 10 to 100 denier, the thickness of the yarn used for the surface layer and the bottom layer is a manufacturing method of eco-friendly sheet fabrics, characterized in that 20 to 200 denier. The method of claim 5, In the weaving step, Eco-friendly sheet fabric manufacturing method characterized in that the back layer is made of a mesh structure. The method of claim 5, In the mixing step, The adhesive resin is a hot melt, solid content, a method for producing an eco-friendly sheet fabric, characterized in that the adhesive is bonded in the form of a water-soluble adhesive. The method of claim 9, The adhesive resin is a method for producing an eco-friendly sheet fabric, characterized in that at least one selected from the group consisting of polyester, polyethylene, polyolefin, such as polypropylene, polyamide, polyacrylic, polyurethane.

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