U.S. patent application number 13/913080 was filed with the patent office on 2014-01-02 for knit spacer fabric for motor-vehicle interior.
The applicant listed for this patent is Frank MUELLER, Stefan MUELLER. Invention is credited to Frank MUELLER, Stefan MUELLER.
Application Number | 20140000319 13/913080 |
Document ID | / |
Family ID | 49667845 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140000319 |
Kind Code |
A1 |
MUELLER; Stefan ; et
al. |
January 2, 2014 |
KNIT SPACER FABRIC FOR MOTOR-VEHICLE INTERIOR
Abstract
The invention relates to spacer fabric comprising a first and a
second generally planar knitted layer (1, 2) that are attached to
each other by spacer threads (3), wherein the spacer threads (3) in
the first knitted layer (1) form stitches by an intertwining of
threads. According to the invention, the spacer threads (3) on the
second generally planar knitted layer (2) do not form stitches,
wherein the spacer threads (3) are interlaced there only as an
inlay. The object of the invention is also a motor vehicle interior
furnishing item that includes this spacer fabric as cover material.
The spacer fabric is disposed in such a way that the second
generally planar knitted layer (2) forms the exposed surface.
Inventors: |
MUELLER; Stefan; (Wiehl,
DE) ; MUELLER; Frank; (Wiehl, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MUELLER; Stefan
MUELLER; Frank |
Wiehl
Wiehl |
|
DE
DE |
|
|
Family ID: |
49667845 |
Appl. No.: |
13/913080 |
Filed: |
June 7, 2013 |
Current U.S.
Class: |
66/191 ; 442/318;
66/196 |
Current CPC
Class: |
D04B 1/22 20130101; D04B
21/16 20130101; Y10T 442/488 20150401; D10B 2501/0632 20130101;
D10B 2403/0213 20130101; D04B 1/02 20130101; D04B 1/16 20130101;
D10B 2403/0114 20130101 |
Class at
Publication: |
66/191 ; 66/196;
442/318 |
International
Class: |
D04B 1/02 20060101
D04B001/02; D04B 1/22 20060101 D04B001/22; D04B 1/16 20060101
D04B001/16 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 13, 2012 |
DE |
102012105134.8 |
Claims
1. In a spacer fabric comprising first and second generally planar
knitted layers that are attached to each other by spacer threads,
the spacer threads forming in the first knitted layer stitches by
an intertwining of threads, the improvement wherein the spacer
threads do not form stitches in the second generally planar knitted
layer and are interlaced there only as an inlay.
2. The spacer fabric according to claim 1, wherein the spacer
threads form between the knitted layers pile loops on the first
knitted layer that each have loop feet created by stitches and a
loop head, the pile loops being held on the loop head on the second
knitted layer.
3. The spacer fabric according to claim claim 1, wherein the second
knitted layer has a knit pattern comprising a perforated
structure.
4. The spacer fabric according to claim 3, wherein holes of the
perforated structure are covered by weft threads on the inside of
the second knitted layer.
5. The spacer fabric according to claim 3, wherein the second
knitted layer has a first stitch-forming and
perforated-structure-generating thread system, and a second
stitch-forming thread system, wherein starting from an exposed
surface of the second knitted layer the stitches formed by the
first thread system are disposed on the stitches formed by the
second thread system, and wherein the spacer threads are held on
the second knitted layer by the second thread system.
6. The spacer fabric according to that claim 1, wherein the knitted
layers and the spacer threads are composed of polyester.
7. The spacer fabric according to claim 1, wherein the fabric meets
the requirements for the hook-and-loop fastener test according to
VDA 230-210.
8. The spacer fabric according to claim 1, wherein the overall
thickness measures between 2.5 mm and 8 mm.
9. The spacer fabric according to that claim 1, wherein the second
knitted layer is bonded by shrinking the corresponding threads at a
setting temperature.
10. Interior furnishing item, in particular, motor vehicle seat or
motor vehicle interior trim, characterized by a spacer fabric in
the form of a cover material according to claim 1.
11. The spacer fabric according to claim 1, wherein the knitted
layers and the spacer threads are composed of PET.
Description
[0001] The invention relates to a spacer fabric comprising a first
and second generally planar knitted layer that are attached to each
other by spacer threads.
[0002] Generic spacer fabrics have been disclosed, for example, in
DE 199 03 070 and DE 90 16 062. The known spacer fabrics are
employed as soft, elastic layers, and layers that provide air
circulation, in mattresses, upholstered furniture, items of
clothing, or shoes. In addition, spacer fabrics find widespread use
in the automotive field, such as, for example, for
climate-controlled seats and seat covers where the spacer fabrics
allow for effective adaptation to contours due to their superior
recovery properties. For example, spacer fabrics are thus an
alternative, for example, to foam padding where a wear-resistant
cover layer of leather or cloth is typically provided.
[0003] In the known spacer fabrics, the spacer threads are
interlaced in the same way in both knitted layers, specifically,
such that spacer threads in the first knitted layer and in the
second knitted layer form stitches due to the intertwining of
threads. The spacer threads here are intertwined with each other
and/or with the threads of the knitted layers. The formation of
stitches in the knitted layers enables the spacer threads to be
strongly interlaced and aligned, thereby providing the requisite
compressive strength.
[0004] Despite the fact that spacer fabrics have proven quite
successful in practical use, there remains a need to enhance their
resistance to mechanical stresses. The known spacer fabrics, in
particular, entail the danger that individual threads can be pulled
out under mechanical stress, thereby degrading the spacer fabrics
both in terms of appearance and functionality. This danger exists,
in particular, whenever the spacer fabrics are exposed to pointed
objects or even hook-and-loop fasteners that are often used in
items of clothing.
[0005] For practical applications, padding materials undergo
hook-and-loop fastener tests in which the sensitivity of padding
materials are tested by a procedure approximating real use for wear
and tear caused by hook-and-loop fasteners. Based on DIN EN ISO
12947-1, the German Automotive Industry Association (VDA) has
issued Test Specification VDA 230-210 of December 2008. The test
sample is subjected to applied stresses by a hook strip, type 751,
after which an assessment is made by visual inspection and a grade
is given based on five grade levels. No changes to the surface
results in a score of grade 5, whereas complete destruction of the
surface and the structure is assessed with a grade of 1. Based on
this referenced test specification, the goal is a grade of 5 for a
padding material that is suitable for long-term use in a motor
vehicle, and this goal is difficult to achieve using known spacer
fabrics, with the result that the known designs of vehicle seats
are always provided with an additional cover layer such as one
composed, for example, of cloth, leather, or artificial
leather.
[0006] In light of the above, the object of this invention is to
provide a spacer fabric that has enhanced resistance to wear from
mechanical stresses. In particular, the object is to provide a
spacer fabric that can also be employed as a cover layer for a
motor vehicle interior where this spacer fabric does not
structurally degrade when used in the motor vehicle.
[0007] Based on a spacer fabric having the above-described
features, the object of the invention is attained in that the
spacer threads do not form stitches on the second generally planar
knitted layer and are only interlaced there as an inlay. What is
understood by this within the scope of the invention is that the
spacer threads are held on the second knitted layer by at least one
associated thread without thereby forming a stitch by intertwining.
The spacer threads are thus threaded through in each case on at
least one thread of the second knitted layer.
[0008] The second generally planar knitted layer in the spacer
fabric according to the invention is provided as the exterior wear
layer that is exposed to mechanical stresses, for example,
hook-and-loop fasteners. The fact that the spacer threads are
interlaced only as an inlay prevents a situation where these
threads run along the exposed surface of the second knitted layer,
and can thereby be caught by hook-and-loop hooks or other pointed
objects and pulled out. Since the spacer threads are interlaced
only as an inlay, these threads can run along the inside of the
second knitted layer with the result that the threads of the second
knitted layer essentially cover and thus protect the spacer
threads.
[0009] An additional advantage to be considered is the fact that
the spacer threads in the described embodiment are also not visible
on the exposed surface of the second knitted layer. One aspect that
must be considered here is that different thread types are
typically used for a thread system of the second knitted layer on
the one side and for the spacer threads on the other side. As a
result, the spacer threads often are monofilaments so as to achieve
a high compressive strength, whereas multifilaments are preferably
used for the cover layers. Within the scope of the invention,
multifilament flat yarn is, in particular, well-suited for the
second generally planar knitted layer, as such yarn thus does not
swell out and accordingly has no texture.
[0010] In terms of the different described thread types for the
second generally planar knitted layer and for the spacer threads,
it is not possible to easily match these precisely for color. In
addition to the color per se, another visual effect is also
achieved. Since the spacer threads according to the invention are
interlaced only on the inside as an inlay on the second generally
planar knitted layer, these threads are not visible and cannot
result in visual variation compared with the threads of the second
knitted layer.
[0011] It is of critical importance for the invention that the
spacer threads in the first knitted layer on the one hand and in
the second knitted layer on the other hand are interlaced
differently. Since the spacer threads in the first knitted layer
form stitches due to thread intertwining either with each other
and/or with the threads of the first knitted layers, it is possible
to achieve superior resistance under load for the spacer threads.
The spacer threads here preferably form pile loops between the
knitted layers, which loops each have loop feet created by stitches
on the first knitted layer, and a loop head between the pile loops,
the pile loops on the loop head being held on the second knitted
layer.
[0012] The second knitted layer according to the invention can have
a knit pattern comprising a perforated structure. This perforated
structure is both visually attractive and is also especially well
suited for dissipating moisture and water vapor. In order, however,
to ensure that relatively large particles of dirt or the like
cannot penetrate into the spacer fabric, according to a preferred
development of the invention holes of the perforated structure on
the inside of the second knitted layer are covered by separate
threads, in particular, by weft threads that run perpendicular to
the knit direction. The shape of the holes according to the
invention can vary. They can be round, oval, rhombic, or roughly
rectangular.
[0013] Since the perforated structure can be generated with high
uniformity, these weft threads can be matched in terms of color to
the thread system of the second generally planar knitted layer, or
can also optionally be of contrasting color. A color contrast
provides an especially easy way to produce an attractive and vivid
design.
[0014] If the spacer fabric has a perforated structure, a preferred
development of the invention provides an approach wherein the
second knitted layer has a first stitch-forming and
perforated-structure-generating thread system plus a second
stitch-forming thread system, where starting from the exposed
surface of the second knitted layer the stitches formed by the
first thread system are on the stitches formed by the second thread
system and the spacer threads are held on the second knitted layer
only by the second thread system. Providing a first thread system
and a second thread system enables the above-described advantages
to be further reinforced. The stitches lying on the outer surface
of the first thread system create optimal protection for the spacer
threads that are underneath on the stitches of the second thread
system.
[0015] As has already been described above, the spacer threads are
preferably monofilaments, while the knitted layers can be composed
both of monofilament threads and also multifilament threads,
multifilament threads allowing a finer, more uniform surface
structure to be produced. Especially well-suited are threads
composed of polyester, where the especially preferred approach is
for both knitted layers and the spacer threads to be entirely
composed of polyester threads, thereby also enabling the spacer
fabrics to be readily recycled. An especially appropriate polyester
is polyethylene terephthalate (PET).
[0016] The spacer fabric according to the invention is
characterized by improved resistance to wear from mechanical
stresses. In a preferred embodiment of the invention, the spacer
fabric meets the requirements of the hook-and-loop fastener test
according to VDA 230-210 when the exposed surface of the second
knitted layer undergoes this test. The spacer fabric meets the
requirements of the hook-and-loop fastener test if the grade of 4,
preferably, a grade of 5 is achieved.
[0017] Due to its resistance to wear, the spacer fabric according
to the invention can also be used as a fabric cover layer in highly
stressed areas. In addition, however, the fabric has the typical
elastic recovery properties of a spacer fabric, as well as a light,
open, and breathable structure. The overall thickness can measure,
for example, between 2.5 mm and 8 mm for the above applications,
although this invention is not restricted to this preferred
range.
[0018] In order to achieve the densest, strongest, and most robust
structure possible, the second knitted layer can be bonded by
shrinking the relevant threads at a setting temperature. Yarns are
used for this purpose that undergo noticeable shrinkage at an
appropriate temperature, with the result that the stitches formed
are also pulled tight. If the second generally planar knitted layer
is provided with a perforated structure, this approach also yields
relatively small uniform holes. In a preferred development of the
invention, the yarns for the second knitted layer and the setting
temperature are selected so that following the knitting process the
yarns of the second knitted layer shrink at least 5%, especially
preferably, 10% due to the corresponding effect of the
temperature.
[0019] The invention also relates to an interior furnishing, such
as, for example, a vehicle seat or the interior trim of a vehicle
that include the described spacer fabric as cover material. Other
possible applications are, for example, the seats or the interior
trim of aircraft or rail-based vehicles such as railroads, subways,
or the like. Specifically in the case of aircraft, there is a
desire to use the lightest possible, most-space-saving possible
seats in order to reduce total flying weight and also to have the
ability to provide sufficient space for the greatest number of
passengers. In addition, the interior furnishing can also relate to
an item of furniture such as a chair.
[0020] The second generally planar knitted layer then provides the
surface of the interior furnishing, that is, in particular, for the
motor vehicle seat or motor vehicle interior. Due to the enhanced
resistance to wear, even hook-and-loop fasteners, or other rough or
sharp-edged objects are not able to damage the interior furnishing
item, or at least only able to damage this only very little. In
particular, there is no need to provide a multilayer design in
which the spacer fabric is covered by a second cover material.
Producing this type of interior furnishing, but also the disposal
and recycling of the interior furnishing is thus made considerably
easier. Finally, it is also possible to reduce production costs
since there is no need to use the expensive approach of combining
different materials, for which purpose an adhesive is typically
used.
[0021] Due to its wear-resistant surface, the fabric according to
the invention thus provides an additional function in that the
additional advantages, specifically, the elastic recovery
properties and the breathability are maintained. In particular, the
invention enables the resistance to wear, the elastic properties,
and the permeability to air to be adapted to and optimized for the
specific relevant specific requirements.
[0022] The following describes the invention with reference to a
drawing that shows only one illustrated embodiment. Therein:
[0023] FIG. 1 is a schematic view of a spacer fabric that includes
two generally planar knitted layers which are attached to each
other by spacer threads;
[0024] FIG. 2 shows the interlacing of the spacer threads in the
first generally planar knitted layer;
[0025] FIG. 3 shows the interlacing of the spacer threads in the
second generally planar knitted layer;
[0026] FIG. 4 is another view like FIG. 3; and
[0027] FIG. 5 is a detail of the surface of the spacer fabric at
the second generally planar knitted layer.
[0028] FIG. 1 provides a schematic view of a spacer fabric that
includes a first generally planar knitted layer 1 and a second
generally planar knitted layer 2 that are attached to each other by
spacer threads 3. FIG. 1 also clearly reveals that the second
knitted layer 2 has a perforated structure with holes 4 that are
covered by weft threads 5 on the inner side, that is, the side
facing the first knitted layer 1. The exposed surface of the second
knitted layer 2 is also illustrated in FIG. 5. The weft threads 5
can thus be interlaced such that they do not extend across the
entire width of the second knitted layer 2 but only across some of
the wales. Depending on the production method, it is possible,
however, for the weft threads to be pulled completely through
transversely, thereby producing what is known as filling.
[0029] According to the invention, the spacer threads 3 form
stitches (FIG. 2) in the first knitted layer 1 by an intertwining
of threads to each other and/or to the threads of the first knitted
layer 1, whereas the spacer threads 3 on the second knitted layer 2
do not form stitches and are interlaced there only as an inlay
(FIGS. 3 and 4). This means that the spacer threads 3 on the second
knitted layer 2 are held by at least one associated thread of the
second knitted layer but forming a stitch by intertwining. For
purposes of clarity, the first knitted layer 1 in FIG. 2 is shown
only in highly schematic fashion. Notwithstanding the highly
schematic representation, this in fact is a typical knitted layer
composed of stitches forming wales running in the production
direction and stitch courses transverse thereto. For the sake of
simplicity, these wales and stitch courses are shown in FIG. 2
without reproducing the actual courses of the individual stitches
of the first knitted layer 1.
[0030] A comparison of FIGS. 2 and 3 shows that the spacer threads
3 form pile loops 6 as a result of the described interlacing in the
first knitted layer 1 and the second knitted layer 2, these loops
each including loop feet created by stitches on the first knitted
layer 1 and a loop head 8 between the feet held on the second
knitted layer 2. Although the loop head is attached to the second
knitted layer 2 as a result of the interlacing of loop head 8 as an
inlay, the course of pile loop 6 is nevertheless essentially
unchanged by the interlacing in the second knitted layer 2
[0031] A critical feature of the invention is that the spacer
threads 3 on the second knitted layer 2 run only along the inner
face and are thus not accessible from the exposed surface of the
second knitted layer 2. The spacer threads 3 on the second knitted
layer 2 are thus well protected against mechanical stresses caused
by a hook-and-loop fastener or by other hook-like, pointed
objects.
[0032] The entire spacer fabric can be composed of polyester, in
particular, PET. The detail views of FIGS. 2 and 3 show that the
spacer threads 3 are monofilaments, whereas the first knitted layer
1 and the second knitted layer 2 are each composed of multifilament
yarns.
[0033] In the described illustrated embodiment, the second knitted
layer 2 includes a first stitch-forming and
perforated-structure-generating thread system 9, and a second
stitch-forming thread system 10, wherein starting from the exposed
surface of the second knitted layer 2 the stitches formed by first
thread system 9 are disposed on the stitches formed by second
thread system 10, and wherein the spacer threads 3 on the second
knitted layer 2 are held only by second thread system 10.
[0034] The described measures enable a spacer fabric to be provided
that meets the requirements of the hook-and-loop fastener test
according to DIN VDA 230-210. The overall thickness of the spacer
fabric can measure, for example, between 2.5 mm and 8 mm.
* * * * *