U.S. patent application number 15/860543 was filed with the patent office on 2018-09-27 for method for forming three-dimensional patterns using double raschel knitted fabric.
The applicant listed for this patent is Kyung Suk CHOI, Ji Sang JANG, Jae Jung LEE. Invention is credited to Kyung Suk CHOI, Ji Sang JANG, Jae Jung LEE.
Application Number | 20180274140 15/860543 |
Document ID | / |
Family ID | 63450154 |
Filed Date | 2018-09-27 |
United States Patent
Application |
20180274140 |
Kind Code |
A1 |
JANG; Ji Sang ; et
al. |
September 27, 2018 |
Method for Forming Three-Dimensional Patterns using Double Raschel
Knitted Fabric
Abstract
The present invention relates to a method for forming a
three-dimensional pattern using a double Raschel knitted fabric,
and more particularly, to a method for forming a three-dimensional
pattern using a double Raschel knitted fabric, in which the
facilitation of formation of visually aesthetic patterns can be
ensured through a simple process during the surface-molding of the
double Raschel knitted fabric having a feeling of volume and a
cushion feeling, and in which the double Raschel knitted fabric can
be given an adhesive property or a high abrasion resistance, or an
adhesive property and a high abrasion resistance.
Inventors: |
JANG; Ji Sang; (Busan,
KR) ; LEE; Jae Jung; (Busan, KR) ; CHOI; Kyung
Suk; (Busan, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JANG; Ji Sang
LEE; Jae Jung
CHOI; Kyung Suk |
Busan
Busan
Busan |
|
KR
KR
KR |
|
|
Family ID: |
63450154 |
Appl. No.: |
15/860543 |
Filed: |
January 2, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2505/08 20130101;
D04B 21/16 20130101; D04B 21/06 20130101; D10B 2403/0222 20130101;
D04B 27/08 20130101; D10B 2401/041 20130101; D10B 2403/0114
20130101 |
International
Class: |
D04B 21/06 20060101
D04B021/06; D04B 27/08 20060101 D04B027/08 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 21, 2017 |
KR |
10-2017-0035567 |
Claims
1. A method for forming a three-dimensional pattern using a double
Raschel knitted fabric composed of an upper layer L1, a lower layer
L2, and an intermediate layer L3 that interconnects the upper and
layer L1 and the lower layer L2, the method comprising
surface-molding the double Raschel knitted fabric into the
three-dimensional pattern by compressing the surface of the double
Raschel knitted fabric at a temperature of 100-200.degree. C. and a
pressure of 10-70 kg/cm.sup.2 for 10-60 seconds using a mold formed
with an engraved part so that a protruded part 20a is formed at a
portion of the double Raschel knitted fabric, which corresponds to
the engraved part of the mold, and a compressed part 20b is formed
at the remaining portion other than the protruded part 20a of the
double Raschel knitted fabric to thereby form the three-dimensional
pattern.
2. The method according to claim 1, wherein the upper layer L1 of
the double Raschel knitted fabric is formed of a TPU yarn 22,
wherein the lower layer L2 thereof is formed of a yarn 21 coated
with a hotmelt resin, wherein the intermediate layer L3 thereof is
formed of a fabric yarn 23, wherein the yarn 21 coated with a
hotmelt resin is formed such that a hotmelt resin 21d is coated on
the outer surface of a fabric yarn 21c consisting of a core 21a and
a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric
yarn 21c is selected from among a polyester yarn, a nylon yarn, and
a cotton yarn, which are used alone or in combination of two or
more thereof, and wherein the hotmelt resin 21d is selected from
among a polyester resin, a polyurethane resin, an acrylic resin, a
polyimide resin, an ethylene vinyl acetate resin, and a polyolefin
resin, which are used alone or in combination of two or more
thereof.
3. The method according to claim 1, wherein the upper layer L1 and
the intermediate layer L3 of the double Raschel knitted fabric are
formed of a fabric yarn 23, wherein the lower layer L2 thereof is
formed of a yarn 21 coated with a hotmelt resin, wherein the yarn
21 coated with a hotmelt resin is formed such that a hotmelt resin
21d is coated on the outer surface of a fabric yarn 21c consisting
of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2,
wherein the fabric yarn 21c is selected from among a polyester
yarn, a nylon yarn, and a cotton yarn, which are used alone or in
combination of two or more thereof, and wherein the hotmelt resin
21d is selected from among a polyester resin, a polyurethane resin,
an acrylic resin, a polyimide resin, an ethylene vinyl acetate
resin, and a polyolefin resin, which are used alone or in
combination of two or more thereof.
4. The method according to claim 1, wherein the upper layer L1 of
the double Raschel knitted fabric is formed of a yarn 21 coated
with a hotmelt resin, wherein the lower layer L2 and the
intermediate layer L3 thereof are formed a fabric yarn 23, wherein
the yarn 21 coated with a hotmelt resin is formed such that a
hotmelt resin 21d is coated on the outer surface of a fabric yarn
21c consisting of a core 21a and a sheath 21b in an amount of
0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from
among a polyester yarn, a nylon yarn, and a cotton yarn, which are
used alone or in combination of two or more thereof, and wherein
the hotmelt resin 21d is selected from among a polyester resin, a
polyurethane resin, an acrylic resin, a polyimide resin, an
ethylene vinyl acetate resin, and a polyolefin resin, which are
used alone or in combination of two or more thereof.
5. The method according to claim 1, wherein the upper layer L1 and
the lower layer L2 of the double Raschel knitted fabric are formed
of a yarn 21 coated with a hotmelt resin, wherein the intermediate
layer L3 thereof is formed a fabric yarn 23, wherein the yarn 21
coated with a hotmelt resin is formed such that a hotmelt resin 21d
is coated on the outer surface of a fabric yarn 21c consisting of a
core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2,
wherein the fabric yarn 21c is selected from among a polyester
yarn, a nylon yarn, and a cotton yarn, which are used alone or in
combination of two or more thereof, and wherein the hotmelt resin
21d is selected from among a polyester resin, a polyurethane resin,
an acrylic resin, a polyimide resin, an ethylene vinyl acetate
resin, and a polyolefin resin, which are used alone or in
combination of two or more thereof.
6. The method according to claim 1, wherein the upper layer L1 of
the double Raschel knitted fabric is formed of a yarn 21 coated
with a hotmelt resin, wherein the lower layer L2 thereof is formed
of a TPU yarn 22, wherein the intermediate layer L3 thereof is
formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt
resin is formed such that a hotmelt resin 21d is coated on the
outer surface of a fabric yarn 21c consisting of a core 21a and a
sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric
yarn 21c is selected from among a polyester yarn, a nylon yarn, and
a cotton yarn, which are used alone or in combination of two or
more thereof, and wherein the hotmelt resin 21d is selected from
among a polyester resin, a polyurethane resin, an acrylic resin, a
polyimide resin, an ethylene vinyl acetate resin, and a polyolefin
resin, which are used alone or in combination of two or more
thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent
Application No. 10-2017-0035567, filed on Mar. 21, 2017 in the
Korean Intellectual Property Office, which is incorporated herein
by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a method for forming a
three-dimensional pattern using a double Raschel knitted fabric, in
which the facilitation of formation of visually aesthetic patterns
can be ensured through a simple process during the surface-molding
of the double Raschel knitted fabric having a feeling of volume and
a cushion feeling, and in which the double Raschel knitted fabric
can be given an adhesive property or a high abrasion resistance, or
an adhesive property and a high abrasion resistance.
2. Description of Related Art
[0003] In general, a double Raschel knitted fabric is a knitted
fabric knitted by a typical double Raschel warp knitting machine
through a knitting process, i.e., a warp knitting method in which a
whole fabric texture is formed in a warp direction, i.e., in a
vertical direction in the knitting process.
[0004] As a related art, Patent Document 1 discloses a method for
manufacturing a double Raschel knitted fabric including an upper
layer, a lower layer, and an intermediate layer that interconnects
the upper and layer and the lower layer using a double Raschel warp
knitting machine.
[0005] Specifically, the upper layer is knitted by allowing a
plurality of surface yarn groups to form loops together with each
other in such a manner that a first surface yarn group as any one
of the surface yarn groups does not form loops together with the
other surface yarn groups from at constant floating sections to
form transverse corrugations at positions corresponding to the
floating sections, that a tension of the first surface yarn group
passing through the floating sections is greater than that of the
first surface yarn group passing through loop sections other than
the floating sections, and that the speed of the first surface yarn
group supplied to the floating sections is lower than that of the
first surface yarn group supplied to the loop sections to adjust
the tension of the first surface yarn group passing through the
floating sections.
[0006] However, such a conventional double Raschel knitted fabric
entails a problem in that the upper layer, the lower layer and the
intermediate layer are formed of only a typical fabric yarn (for
example, mono yarn, polyester yarn, nylon yarn or cotton yarn), and
as a result, a feeling of volume and a cushion feeling are
implemented but an adhesive property or a high abrasion resistance
or the facilitation of formation of patterns during the
surface-molding of the double Raschel knitted fabric is not
implemented.
[0007] In the meantime, the above conventional double Raschel
knitted fabric is applied to various kinds of mats or seats, and is
typically manufactured by bonding a cover fabric formed with a
variety of patterns to the top surface of the upper layer of the
double Raschel knitted fabric by means of an adhesive and sewing
the cover fabric according to the shapes of the patterns formed on
the cover fabric. However, a mat or seat to which the above
conventional double Raschel knitted fabric is applied have problems
in that a lower layer (i.e., a layer contacting with a bottom
surface) thereof is formed of only a typical fabric yarn (for
example, mono yarn, polyester yarn, nylon yarn or cotton yarn), and
as a result, a non-slip property of the mat or seat is very poor
and thus the mat or seat easily slips on the bottom surface,
thereby causing the occurrence of various kinds of safety accidents
or an inconvenience in use.
PRIOR ART LITERATURE
Patent Documents
[0008] Patent Document 1: Korean Patent Registration No. 10-0987108
entitled "Method for Manufacturing Double Raschel Knitted Fabric
formed with transverse corrugations and Double Raschel Knitted
Fabric Manufactured thereby"
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention has been made to solve
the aforementioned problems occurring in the prior art, and it is
an object of the present invention to provide a method for forming
a three-dimensional pattern using a double Raschel knitted fabric,
in which the facilitation of formation of visually aesthetic
patterns can be ensured through a simple process during the
surface-molding of the double Raschel knitted fabric having a
feeling of volume and a cushion feeling, and in which the double
Raschel knitted fabric can be given an adhesive property or a high
abrasion resistance, or an adhesive property and a high abrasion
resistance.
[0010] Specifically, another object of the present invention is to
provide a method for forming a three-dimensional pattern using a
double Raschel knitted fabric, in which in the double Raschel
knitted fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer L1 and
the lower layer, the upper layer L1 is formed of a TPU
(Thermoplastic Polyurethane) yarn, the lower layer L2 is formed of
a yarn coated with a hotmelt resin, and the intermediate layer is
formed of a fabric yarn (jet spun yarn) so that the double Raschel
knitted fabric can be given a feeling of volume and a cushion
feeling, and an adhesive property, as well as the facilitation of
formation of patterns can be ensured during the surface-molding of
the double Raschel knitted fabric and an abrasion resistance of the
double Raschel knitted fabric can be improved.
[0011] Still another object of the present invention is to provide
a method for forming a three-dimensional pattern using a double
Raschel knitted fabric, in which in the double Raschel knitted
fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer and the
lower layer, the upper layer is formed of a TPU yarn, and the lower
layer and the intermediate layer are formed of a general fabric
yarn so that the double Raschel knitted fabric can be given a
feeling of volume and a cushion feeling, as well as the
facilitation of formation of patterns can be ensured during the
surface-molding of the double Raschel knitted fabric and an
abrasion resistance of the double Raschel knitted fabric can be
improved.
[0012] Yet another object of the present invention is to provide a
method for forming a three-dimensional pattern using a double
Raschel knitted fabric, in which in the double Raschel knitted
fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer and the
lower layer, the upper layer and the intermediate layer are formed
of a general fabric yarn, and the lower layer is formed of a yarn
coated with a hotmelt resin so that the double Raschel knitted
fabric can be given a feeling of volume and a cushion feeling, and
an adhesive property, as well as the facilitation of formation of
patterns can be ensured during the surface-molding of the double
Raschel knitted fabric.
[0013] A further object of the present invention is to provide a
method for forming a three-dimensional pattern using a double
Raschel knitted fabric, in which in the double Raschel knitted
fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer and the
lower layer, the upper layer is formed of a yarn coated with a
hotmelt resin, and the lower layer and the intermediate layer are
formed of a general fabric yarn so that the double Raschel knitted
fabric can be given a feeling of volume and a cushion feeling, as
well as the facilitation of formation of patterns can be ensured
during the surface-molding of the double Raschel knitted fabric and
an abrasion resistance of the double Raschel knitted fabric can be
improved.
[0014] A still further object of the present invention is to
provide a method for forming a three-dimensional pattern using a
double Raschel knitted fabric, in which in the double Raschel
knitted fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer and the
lower layer, the upper layer and the lower layer are formed of a
yarn coated with a hotmelt resin, and the intermediate layer is
formed of a general fabric yarn so that the double Raschel knitted
fabric can be given a feeling of volume and a cushion feeling, and
an adhesive property, as well as the facilitation of formation of
patterns can be ensured during the surface-molding of the double
Raschel knitted fabric and an abrasion resistance of the double
Raschel knitted fabric can be improved.
[0015] A yet further object of the present invention is to provide
a method for forming a three-dimensional pattern using a double
Raschel knitted fabric, in which in the double Raschel knitted
fabric composed of an upper layer, a lower layer, and an
intermediate layer that interconnects the upper and layer and the
lower layer, the upper layer is formed of a yarn coated with a
hotmelt resin, the lower layer is formed of a TPU yarn, and the
intermediate layer is formed of a fabric yarn so that the double
Raschel knitted fabric can be given a feeling of volume and a
cushion feeling, an adhesive property and an abrasion resistance,
as well as the facilitation of formation of patterns can be ensured
during the surface-molding of the double Raschel knitted fabric,
and formability and thus the aesthetic value of the exterior
appearance of the double Raschel knitted fabric can be
improved.
[0016] Another further object of the present invention is to
provide a method for forming a three-dimensional pattern using a
double Raschel knitted fabric, in which various kinds of mats or
seats are manufactured by using the double Raschel knitted fabric
including a lower layer (i.e., a layer contacting with a bottom
surface) formed of a yarn coated with a hotmelt resin or a TPU yarn
so that the non-slip property of the mats or seats can be improved
by the lower layer, thereby preventing a variety of safety
accidents and improving a convenience in use.
[0017] More specifically, another yet further object of the present
invention is to provide a method for forming a three-dimensional
pattern using a double Raschel knitted fabric, in which a cover
fabric formed with a variety of patterns is bonded to the top
surface of the upper layer of the double Raschel knitted fabric
including a lower layer formed of a hotmelt resin-coated yarn or a
TPU yarn by means of an adhesive and is sewn according to the
shapes of the patterns formed on the cover fabric to manufacture
various kinds of mats or seats so that the non-slip property can be
implemented and the adhesive strength of the cover fabric and the
double Raschel knitted fabric can be implemented more strongly and
easily.
[0018] To achieve the above objects, the present invention provides
a method for forming a three-dimensional pattern using a double
Raschel knitted fabric composed of an upper layer L1, a lower layer
L2, and an intermediate layer L3 that interconnects the upper and
layer L1 and the lower layer L2, the method comprising
surface-molding the double Raschel knitted fabric into the
three-dimensional pattern by compressing the surface of the double
Raschel knitted fabric at a temperature of 100-200.degree. C. and a
pressure of 10-70 kg/cm.sup.2 for 10-60 seconds using a mold formed
with an engraved part so that a protruded part 20a is formed at a
portion of the double Raschel knitted fabric, which corresponds to
the engraved part of the mold, and a compressed part 20b is formed
at the remaining portion other than the protruded part 20a of the
double Raschel knitted fabric to thereby form the three-dimensional
pattern.
[0019] Meanwhile, the upper layer L1 of the double Raschel knitted
fabric may be formed of a TPU fabric 22, the lower layer L2 may be
formed of a fabric 21 coated with a hotmelt resin, and the
intermediate layer L3 may be formed of a fabric yarn 23. The yarn
21 coated with a hotmelt resin may be formed such that a hotmelt
resin 21d is coated on the outer surface of a fabric yarn 21c
consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3
g/m.sup.2. The fabric yarn 21c may be selected from among a
polyester yarn, a nylon yarn, and a cotton yarn, which are used
alone or in combination of two or more thereof. The hotmelt resin
21d may be selected from among a polyester resin, a polyurethane
resin, an acrylic resin, a polyimide resin, an ethylene vinyl
acetate resin, and a polyolefin resin, which are used alone or in
combination of two or more thereof.
[0020] In addition, the upper layer L1 and the intermediate layer
L3 of the double Raschel knitted fabric may be formed of a fabric
yarn 23, and the lower layer L2 thereof may be formed of a yarn 21
coated with a hotmelt resin. The yarn 21 coated with a hotmelt
resin may be formed such that a hotmelt resin 21d is coated on the
outer surface of a fabric yarn 21c consisting of a core 21a and a
sheath 21b in an amount of 0.03-0.3 g/m.sup.2. The fabric yarn 21c
may be selected from among a polyester yarn, a nylon yarn, and a
cotton yarn, which are used alone or in combination of two or more
thereof. The hotmelt resin 21d may be selected from among a
polyester resin, a polyurethane resin, an acrylic resin, a
polyimide resin, an ethylene vinyl acetate resin, and a polyolefin
resin, which are used alone or in combination of two or more
thereof.
[0021] In addition, the upper layer L1 of the double Raschel
knitted fabric may be formed of a yarn 21 coated with a hotmelt
resin, and the lower layer L2 and the intermediate layer L3 thereof
may be formed a fabric yarn 23. The yarn 21 coated with a hotmelt
resin may be formed such that a hotmelt resin 21d is coated on the
outer surface of a fabric yarn 21c consisting of a core 21a and a
sheath 21b in an amount of 0.03-0.3 g/m.sup.2. The fabric yarn 21c
may be selected from among a polyester yarn, a nylon yarn, and a
cotton yarn, which are used alone or in combination of two or more
thereof. The hotmelt resin 21d may be selected from among a
polyester resin, a polyurethane resin, an acrylic resin, a
polyimide resin, an ethylene vinyl acetate resin, and a polyolefin
resin, which are used alone or in combination of two or more
thereof.
[0022] In addition, the upper layer L1 and the lower layer L2 of
the double Raschel knitted fabric may be formed of a yarn 21 coated
with a hotmelt resin, and the intermediate layer L3 thereof may be
formed a fabric yarn 23. The yarn 21 coated with a hotmelt resin
may be formed such that a hotmelt resin 21d is coated on the outer
surface of a fabric yarn 21c consisting of a core 21a and a sheath
21b in an amount of 0.03-0.3 g/m.sup.2. The fabric yarn 21c may be
selected from among a polyester yarn, a nylon yarn, and a cotton
yarn, which are used alone or in combination of two or more
thereof. The hotmelt resin 21d may be selected from among a
polyester resin, a polyurethane resin, an acrylic resin, a
polyimide resin, an ethylene vinyl acetate resin, and a polyolefin
resin, which are used alone or in combination of two or more
thereof.
[0023] In addition, the upper layer L1 of the double Raschel
knitted fabric may be formed of a yarn 21 coated with a hotmelt
resin, the lower layer L2 thereof may be formed of a TPU yarn 22,
and the intermediate layer L3 thereof may be formed a fabric yarn
23. The yarn 21 coated with a hotmelt resin may be formed such that
a hotmelt resin 21d is coated on the outer surface of a fabric yarn
21c consisting of a core 21a and a sheath 21b in an amount of
0.03-0.3 g/m.sup.2. The fabric yarn 21c may be selected from among
a polyester yarn, a nylon yarn, and a cotton yarn, which are used
alone or in combination of two or more thereof. The hotmelt resin
21d may be selected from among a polyester resin, a polyurethane
resin, an acrylic resin, a polyimide resin, an ethylene vinyl
acetate resin, and a polyolefin resin, which are used alone or in
combination of two or more thereof.
[0024] In the meantime, a cover fabric 200 may be laminated on the
top surface of the upper layer L1 in such a manner that the cover
fabric 200 and the top surface of the upper layer L1 are boned to
each other by means of a hotmelt film.
[0025] As described above, the present invention has an effect in
that the facilitation of formation of visually aesthetic patterns
can be ensured through a simple process during the surface-molding
of the double Raschel knitted fabric having a feeling of volume and
a cushion feeling, and in that the double Raschel knitted fabric
can be given an adhesive property or a high abrasion resistance, or
an adhesive property and a high abrasion resistance.
[0026] In addition, the present invention has an effect in that a
cover fabric formed with a variety of patterns is bonded to the top
surface of the upper layer of the double Raschel knitted fabric
including a lower layer formed of a hotmelt resin-coated yarn or a
TPU yarn by means of an adhesive and is sewn according to the
shapes of the patterns formed on the cover fabric to manufacture
various kinds of mats or seats so that the non-slip property can be
implemented by the lower layer to prevent various kinds of safety
accidents and improve a convenience in use, and the adhesive
strength of the cover fabric and the double Raschel knitted fabric
can be more strongly and easily implemented by the hotmelt
film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other objects, features and advantages of the
present invention will be apparent from the following detailed
description of the preferred embodiments of the invention when
taken in conjunction with the accompanying drawings, in which:
[0028] FIG. 1 is a top plan view showing a state in which a
three-dimensional pattern is formed on the surface of a double
Raschel knitted fabric according to a first embodiment of the
present invention;
[0029] FIG. 2 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a first embodiment of
the present invention;
[0030] FIG. 3 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a second embodiment of
the present invention;
[0031] FIG. 4 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a third embodiment of
the present invention;
[0032] FIG. 5 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a fourth embodiment of
the present invention;
[0033] FIG. 6 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a fifth embodiment of
the present invention;
[0034] FIG. 7 is a cross-sectional view showing a structure of a
double Raschel knitted fabric according to a sixth embodiment of
the present invention;
[0035] FIG. 8 is a cross-sectional view showing a structure of a
yarn coated with a hotmelt resin applied to the present invention;
and
[0036] FIGS. 9 and 10 are cross-sectional views showing a structure
of a double Raschel knitted fabric on which a cover fabric is
laminated according to the present invention.
EXPLANATION ON SYMBOLS
[0037] 20a: protruded part
[0038] 20b: compressed part
[0039] L1: upper layer
[0040] L2: lower layer
[0041] L3: intermediate layer
[0042] 21: yarn coated with a hotmelt resin yarn
[0043] 21a: core
[0044] 21b: sheath
[0045] 21c, 23: fabric yarn
[0046] 21d: hotmelt resin
[0047] 22: TPU yarn
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] The present invention for achieving the above-mentioned
effects is directed to a method for forming a three-dimensional
pattern using a double Raschel knitted fabric. In the meantime, in
the detailed description and the accompanying drawings,
illustration and explanation on the construction and operation
which a person skilled in the art can easily understand will be
briefly made or will be omitted to avoid redundancy. In particular,
illustration and explanation on the detailed technical construction
and operation of elements, which have no direct connection with the
technical features of the present invention, will be omitted, and
only the technical constructions directly related with the present
invention will be briefly illustrated and explained.
[0049] Hereinafter, a method for forming a three-dimensional
pattern using a double Raschel knitted fabric according to the
present invention will be described in detail.
[0050] As shown in FIG. 1, the method for forming a
three-dimensional pattern using a double Raschel knitted fabric
according to the present invention includes surface-molding the
double Raschel knitted fabric into the three-dimensional pattern by
compressing the surface of the double Raschel knitted fabric at a
temperature of 100-200.degree. C. and a pressure of 10-70
kg/cm.sup.2 for 10-60 seconds using a mold formed with an engraved
part (at this time, the types of the mold and the engraved part may
be modified variously depending on designs) so that a protruded
part 20a is formed at a portion of the double Raschel knitted
fabric, which corresponds to the engraved part of the mold, and a
compressed part 20b is formed at the remaining portion (i.e., a
portion where the engraved part of the mold is not formed) other
than the protruded part 20a of the double Raschel knitted fabric to
thereby form the three-dimensional pattern. Herein, if the
surface-molding conditions are out of the above range, the
three-dimensional pattern may not be formed properly.
[0051] In the meantime, in the double Raschel knitted fabric used
in the present invention, which is composed of an upper layer L1, a
lower layer L2, and an intermediate layer L3 that interconnects the
upper and layer L1 and the lower layer L2 to give a feeling of
volume and a cushion feeling, a first embodiment, a fifth
embodiment and a sixth embodiment may be given an adhesive property
(or tackiness) and a high abrasion resistance, a second embodiment
and a fourth embodiment may be given a high abrasion resistance,
and a third embodiment may be given an adhesive property.
[0052] Herein, the double Raschel knitted fabric is produced by a
knitting process as described above. In other words, the double
Raschel knitted fabric is a known knitted fabric knitted by a
typical double Raschel warp knitting machine, i.e., a warp knitting
method in which a whole fabric texture is formed in a warp
direction, i.e., in a vertical direction in the knitting process.
That is, the knitting type, method and apparatus of the double
Raschel knitted fabric have been known in various manners, but are
not particularly limited and any known knitting type, method and
apparatus of the double Raschel knitted fabric can be applied to
the present invention.
[0053] First, in the first embodiment of the present invention, as
shown in FIG. 2, in the double Raschel knitted fabric used in the
present invention, which is composed of an upper layer L1, a lower
layer L2, and an intermediate layer L3 that interconnects the upper
and layer L1 and the lower layer L2 to give a feeling of volume and
a cushion feeling, the upper layer L1 of the double Raschel knitted
fabric is formed of a TPU yarn 22, the lower layer L2 thereof is
formed of a yarn 21 coated with a hotmelt resin, and the
intermediate layer L3 thereof is formed of a fabric yarn (jet spun
yarn) 23.
[0054] In other words, the yarn 21 coated with a hotmelt resin
formed on the lower layer L2 gives an adhesive property to the
double Raschel knitted fabric, the TPU yarn 22 formed on the upper
layer L1 improves an abrasion resistance of the double Raschel
knitted fabric, and the intermediate layer L3 formed of the fabric
yarn 23 gives a feeling of volume and a cushion feeling to the
double Raschel knitted fabric.
[0055] Further, the UPU yarn 22 formed on the upper layer L1
facilitates the formation of patterns during the surface-molding of
the double Raschel knitted fabric.
[0056] In this case, the yarn 21 coated with a hotmelt resin serves
to gives an adhesive property to the double Raschel knitted fabric,
and as shown in FIG. 8, it is formed such that a hotmelt resin 21d
is coated on the outer surface of a fabric yarn 21c consisting of a
core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2. If
the coating content of the hotmelt resin 21d is less than 0.03
g/m.sup.2, the adhesive property may be deteriorated, and if the
coating content of the hotmelt resin 21d exceeds 0.3 g/m.sup.2, a
defect may occur during the double Raschel knitting process due to
an increase in the amount of the hotmelt resin 21d. Meanwhile, the
coating content of the hotmelt resin 21d may vary in the extent
being out of the above range depending on the kind or use
environment of a product applied to the present invention.
[0057] In this case, examples of the fabric yarn 21c included in
the yarn 21 coated with a hotmelt resin may include a polyester
yarn, a nylon yarn, and a cotton yarn, which are used alone or in
combination of two or more thereof, and examples of the hotmelt
resin 21d may include a polyester resin, a polyurethane resin, an
acrylic resin, a polyimide resin, an ethylene vinyl acetate resin,
and a polyolefin resin, which are used alone or in combination of
two or more thereof.
[0058] Herein, each of the examples of the hotmelt resin 21d may be
coated on the fabric yarn 21c irrespective of the kind of the
fabric yarn 21c, but the hotmelt resin 21d and the fabric yarn 21c
may be selected in consideration of the fusion property of the
fabric yarn 21c and the hotmelt resin 21d through the coating
process. In other words, if the polyester yarn is selected as the
fabric yarn 21c, the polyurethane resin is preferably coated as the
hotmelt resin 21d. If the nylon yarn is selected as the fabric yarn
21c, the acrylic resin or the polyimide resin is preferably coated
as the hotmelt resin 21d. In addition, if the cotton yarn is
selected as the fabric yarn 21c, the ethylene vinyl acetate resin
or the polyolefin resin is preferably coated as the hotmelt resin
21d.
[0059] In the meantime, the TPU yarn 22 refers to a yarn produced
by extruding a thermoplastic polyurethane (TPU) resin, which is a
sort of yarn that is already known in the art, and thus a detailed
description thereof will be omitted to avoid redundancy. Further,
it is obvious to those skilled in the art that the TPU yarn 22 is
formed of the above TPU resin so that it is relatively excellent in
its abrasion resistance compared to a general fabric yarn.
[0060] In addition, examples of the fabric yarn 23 used in the
intermediate layer L3 may include a polyester yarn, a nylon yarn, a
mono yarn, and a cotton yarn, which are used alone or in
combination of two or more thereof.
[0061] In addition, in the second embodiment of the present
invention, as shown in FIG. 3, in the double Raschel knitted fabric
used in the present invention, which is composed of an upper layer
L1, a lower layer L2, and an intermediate layer L3 that
interconnects the upper and layer L1 and the lower layer L2 to give
a feeling of volume and a cushion feeling, the upper layer L1 is
formed of a TPU yarn 22, and the lower layer L2 and the
intermediate layer L3 are formed of a fabric yarn 23.
[0062] In other words, the TPU yarn 22 formed on the upper layer L1
improves an abrasion resistance of the double Raschel knitted
fabric, and the intermediate layer L3 formed of the fabric yarn 23
gives a feeling of volume and a cushion feeling to the double
Raschel knitted fabric.
[0063] Further, the UPU yarn 22 formed on the upper layer L1
facilitates the formation of patterns during the surface-molding of
the double Raschel knitted fabric.
[0064] In addition, in the third embodiment of the present
invention, as shown in FIG. 4, in the double Raschel knitted fabric
used in the present invention, which is composed of an upper layer
L1, a lower layer L2, and an intermediate layer L3 that
interconnects the upper and layer L1 and the lower layer L2 to give
a feeling of volume and a cushion feeling, the upper layer L1 and
the intermediate layer L3 of the double Raschel knitted fabric are
formed of a fabric yarn 23, and the lower layer L2 thereof is
formed of a yarn 21 coated with a hotmelt resin.
[0065] In other words, the yarn 21 coated with a hotmelt resin,
formed on the lower layer L2 gives an adhesive property to the
double Raschel knitted fabric, and the intermediate layer L3 formed
of the fabric yarn 23 gives a feeling of volume and a cushion
feeling to the double Raschel knitted fabric.
[0066] Further, in the fourth embodiment of the present invention,
as shown in FIG. 5, in the double Raschel knitted fabric used in
the present invention, which is composed of an upper layer L1, a
lower layer L2, and an intermediate layer L3 that interconnects the
upper and layer L1 and the lower layer L2 to give a feeling of
volume and a cushion feeling, the upper layer L1 of the double
Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt
resin, and the lower layer L2 and the intermediate layer L3 thereof
are formed a fabric yarn 23.
[0067] In other words, the hotmelt resin-coated yarn 21 formed on
the upper layer L1 improves an abrasion resistance of the double
Raschel knitted fabric, and the intermediate layer L3 formed of the
fabric yarn 23 gives a feeling of volume and a cushion feeling to
the double Raschel knitted fabric.
[0068] Further, the hotmelt resin-coated yarn 21 formed on the
upper layer L1 facilitates the formation of patterns during the
surface-molding of the double Raschel knitted fabric.
[0069] In addition, in the fifth embodiment of the present
invention, as shown in FIG. 6, in the double Raschel knitted fabric
used in the present invention, which is composed of an upper layer
L1, a lower layer L2, and an intermediate layer L3 that
interconnects the upper and layer L1 and the lower layer L2 to give
a feeling of volume and a cushion feeling, the upper layer L1 and
the lower layer L2 of the double Raschel knitted fabric are formed
of a yarn 21 coated with a hotmelt resin, and the intermediate
layer L3 thereof is formed a fabric yarn 23.
[0070] In other words, the hotmelt resin-coated yarn 21 formed on
the upper layer L1 improves an abrasion resistance of the double
Raschel knitted fabric, the yarn 21 coated with a hotmelt resin,
formed on the lower layer L2 gives an adhesive property to the
double Raschel knitted fabric, and the intermediate layer L3 formed
of the fabric yarn 23 gives a feeling of volume and a cushion
feeling to the double Raschel knitted fabric.
[0071] Further, the hotmelt resin-coated yarn 21 formed on the
upper layer L1 facilitates the formation of patterns during the
surface-molding of the double Raschel knitted fabric.
[0072] In addition, in the sixth embodiment of the present
invention, as shown in FIG. 7, in the double Raschel knitted fabric
used in the present invention, which is composed of an upper layer
L1, a lower layer L2, and an intermediate layer L3 that
interconnects the upper and layer L1 and the lower layer L2 to give
a feeling of volume and a cushion feeling, the upper layer L1 of
the double Raschel knitted fabric is formed of a yarn 21 coated
with a hotmelt resin, the lower layer L2 thereof is formed of a TPU
yarn 22, and the intermediate layer L3 thereof is formed a fabric
yarn 23.
[0073] In other words, the hotmelt resin-coated yarn 21 formed on
the upper layer L1 improves an abrasion resistance of the double
Raschel knitted fabric, and the intermediate layer L3 formed of the
fabric yarn 23 gives a feeling of volume and a cushion feeling to
the double Raschel knitted fabric.
[0074] Besides, in the sixth embodiment, the knitting structure of
the TPU yarn 22 is visibly observed from the outside of the upper
layer L1 during the forming process due to a difference (typically,
the melting point of the TPU yarn 22 is higher than that of the
hotmelt resin-coated yarn 21) in the melting point between the
hotmelt resin-coated yarn 21 forming the layer L1 and the TPU yarn
22 forming the lower layer L2 so that formability and thus the
aesthetic value of the exterior appearance of the double Raschel
knitted fabric can be improved.
[0075] Further, the hotmelt resin-coated yarn 21 formed on the
upper layer L1 facilitates the formation of patterns during the
surface-molding of the double Raschel knitted fabric.
[0076] In the meantime, the hotmelt resin-coated yarn 21, the TUP
yarn 22 and the fabric yarn 23, which are used in each of the above
embodiments, have been described in the first embodiment, and thus
the detailed description thereof will be omitted to avoid
redundancy.
[0077] Further, in each of the above embodiments, in the case of
the hotmelt resin-coated yarn 21 or the TPU yarn 22 forming the
upper layer L1 or the lower layer L2, the hotmelt resin-coated yarn
21, the TPU yarn 22 and the fabric yarn 23 may be mixed to form
each layer. Specifically, the hotmelt resin-coated yarn 21 may be
mixed with the TPU yarn 22 or the fabric yarn 23, and the TPU yarn
22 may be mixed with the hotmelt resin-coated yarn 21 or the fabric
yarn 23, but are not limited thereto and various yarns or
functional yarns may be mixed.
[0078] In other words, the double Raschel knitted fabric of the
present invention is given an adhesive property and a high abrasion
resistance as in the first embodiment, the fifth embodiment and the
sixth embodiment besides a feeling of volume and a cushion feeling,
or is given an adhesive property as in the third embodiment.
Alternatively, as in the sixth embodiment, formability and thus the
aesthetic value of the exterior appearance of the double Raschel
knitted fabric are improved so that its use range and efficiency
can be further extended.
[0079] Meanwhile, in the double Raschel knitted fabric having the
above structure, as shown in FIGS. 9 and 10, in the case where a
cover fabric 200 is laminated on the top surface of the upper layer
L1 of the double Raschel knitted fabric, the lower layer L2 (i.e.,
a layer contacting with a bottom surface) is formed of the hotmelt
resin-coated yarn 21 or the TPU yarn 22 so that a non-slip property
relative to the bottom surface can be improved, and a variety of
safety accidents can be prevented as well as a convenience in use
can be enhanced in the manufacture of a mat or seat using the
non-slip property.
[0080] In this case, in laminating the cover fabric 200 on the top
surface of the upper layer L1 of the double Raschel knitted fabric,
the cover fabric 200 and the top surface of the double Raschel
knitted fabric are boned to each other by means of a general
hotmelt film so that the adhesive property of the cover fabric 200
can be improved. Further, the double Raschel knitted fabric may be
applied to various kinds of mats or seats by sewing according to
the shape of a pattern formed on the cover fabric 200.
[0081] As described above, while the method for forming a
three-dimensional pattern using a double Raschel knitted fabric
according to the present invention has been described and
illustrated in connection with specific exemplary embodiments with
reference to the accompanying drawings, it will be readily
appreciated by those skilled in the art that various modifications
and changes can be made to the present invention within the
technical spirit and scope of the present invention defined in the
claims.
* * * * *