U.S. patent application number 16/667384 was filed with the patent office on 2020-07-02 for pile knit fabric for interior materials of vehicles, method of manufacturing the same and manufacturing machine of pile knit fab.
This patent application is currently assigned to Hyundai Motor Company. The applicant listed for this patent is Hyundai Motor Company Kia Motors Corporation Kolon Glotech, lnc.. Invention is credited to Hyun Dae CHO, Hong Chan JEON, Hyun Joung JUN, Hong Mo KOO, Oh Deok KWON, Joon Yong SONG, Hyung Joon YOUN, Mi Jung YUN.
Application Number | 20200208309 16/667384 |
Document ID | / |
Family ID | 71121918 |
Filed Date | 2020-07-02 |
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United States Patent
Application |
20200208309 |
Kind Code |
A1 |
KOO; Hong Mo ; et
al. |
July 2, 2020 |
PILE KNIT FABRIC FOR INTERIOR MATERIALS OF VEHICLES, METHOD OF
MANUFACTURING THE SAME AND MANUFACTURING MACHINE OF PILE KNIT
FABRIC
Abstract
A pile knit fabric for internal materials of vehicles may
include a knit layer prepared by weaving ground yarns, on one
surface thereof, and a pile layer prepared by interweaving pile
yarns with ground yarn loops of the knit layer, on the other
surface thereof and, thus, has excellent physical coupling force
between the ground yarns and the pile yarns and has excellent
abrasion resistance, scratch resistance and formability as well as
soft tactility.
Inventors: |
KOO; Hong Mo; (Hwaseong-si,
KR) ; YUN; Mi Jung; (Yongin-si, KR) ; KWON; Oh
Deok; (Hwaseong-si, KR) ; SONG; Joon Yong;
(Hwaseong-si, KR) ; CHO; Hyun Dae; (Seongnam-si,
KR) ; JEON; Hong Chan; (Seoul, KR) ; YOUN;
Hyung Joon; (Seoul, KR) ; JUN; Hyun Joung;
(Gumi-si, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hyundai Motor Company
Kia Motors Corporation
Kolon Glotech, lnc. |
Seoul
Seoul
Yongin-si |
|
KR
KR
KR |
|
|
Assignee: |
Hyundai Motor Company
Seoul
KR
Kia Motors Corporation
Seoul
KR
Kolon Glotech, lnc.
Yongin-si
KR
|
Family ID: |
71121918 |
Appl. No.: |
16/667384 |
Filed: |
October 29, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 1/04 20130101; D06C
11/00 20130101; D06C 2700/15 20130101; D04B 1/16 20130101; D03D
2700/0111 20130101; D03D 2700/60 20130101; D06C 7/00 20130101; D10B
2331/04 20130101; D03D 49/00 20130101; B60R 13/02 20130101; D06C
13/08 20130101; D03D 27/10 20130101; D10B 2505/12 20130101; D03D
39/24 20130101 |
International
Class: |
D03D 27/10 20060101
D03D027/10; D04B 1/04 20060101 D04B001/04; D04B 1/16 20060101
D04B001/16; D06C 7/00 20060101 D06C007/00; D06C 11/00 20060101
D06C011/00; D06C 13/08 20060101 D06C013/08; D03D 39/24 20060101
D03D039/24; D03D 49/00 20060101 D03D049/00; B60R 13/02 20060101
B60R013/02 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 31, 2018 |
KR |
10-2018-0173372 |
Claims
1. A pile knit fabric for internal materials of vehicle, the pile
knit fabric comprising: a knit layer formed of a plurality of
ground yarns woven lengthwise and widthwise into loop shapes; and a
pile layer formed of a plurality of pile yarns interwoven with
ground yarn loops of the knit layer, wherein the knit layer is
prepared by weaving the plurality of ground yarns to form a
double-sided loop structure or a single-sided loop structure; and
wherein the pile layer is fixed to a surface of the knit layer and
prepared by interlacing the plurality of pile yarns with the ground
yarn loops of the knit layer.
2. The pile knit fabric of claim 1, wherein the plurality of ground
yarns or the plurality of pile yarns are formed of one or more
selected from the group consisting of polyamide, polypropylene,
polyethylene terephthalate (PET), wool and combination thereof.
3. The pile knit fabric of claim 1, wherein a number of the ground
yarn loops of the knit layer is 250-950 per meter in a horizontal
direction thereof.
4. The pile knit fabric of claim 1, wherein the plurality of ground
yarns has fineness of 50-200 denier.
5. The pile knit fabric of claim 1, wherein the knit layer has a
thickness of 0.1-2 mm and a weight per area of 40-200
g/m.sup.2.
6. The pile knit fabric of claim 1, wherein one strand of the
plurality of pile yarns includes 10-140 strands of filaments, and
the filaments have fineness of 3-25 denier.
7. The pile knit fabric of claim 1, wherein the plurality of pile
yarns has a length of 2-10 mm.
8. The pile knit fabric of claim 1, wherein the pile layer has a
thickness of 1-9 mm and a weight per area of 100-600 g/m.sup.2.
9. The pile knit fabric of claim 1, wherein the pile knit fabric
has a weight per area of 200-700 g/m.sup.2.
10. A method of manufacturing a pile knit fabric for internal
materials of vehicle, the method comprising: preparing a plurality
of ground yarns and a plurality of pile yarns; weaving the
plurality of ground yarns into loop shapes to intersect each other
lengthwise and widthwise; producing a double woven fabric using a
double Raschel method by interweaving the plurality of pile yarns
with ground yarn loops; producing pile knitted fabrics by cutting
the plurality of pile yarns of the double woven fabric; brushing
the cut pile yarns of the pile knitted fabrics; and performing heat
treatment of the brushed pile knitted fabrics.
11. The method of claim 10, wherein, in the producing the pile
knitted fabrics, the plurality of pile yarns of the double woven
fabric is cut to have a length of 2-10 mm.
12. The method of claim 10, wherein, in the brushing the pile
knitted fabrics, the cut pile knitted fabrics are brushed by
rotating a brush at a rate of 400-800 revolutions per minute (RPM)
and a speed of 4-10 m/min.
13. The method of claim 10, wherein, in the performing heat
treatment of the pile knitted fabrics, the heat treatment is
performed at a temperature of 110-200.degree. C. for 2-10
minutes.
14. A manufacturing machine of a pile knit fabric for internal
materials of vehicle, the machine comprising: a weaving unit
configured to produce a double woven fabric by weaving a plurality
of ground yarns into loop shapes to intersecteach other lengthwise
and widthwise and connecting ground yarn loops by a plurality of
pile yarns through vertical reciprocation; fabric transfer rollers
engaged to the double woven fabric and configured to transfer the
double woven fabric produced by the weaving unit; a cutting unit
configured to produce pile knitted fabrics by cutting the plurality
of pile yarns of the double woven fabric transferred from the
fabric transfer rollers; brushing units receiving the cut pile
yarns of the pile knitted fabrics and configured to brush surfaces
of the cut pile yarns of the pile knitted fabrics; and a heat
treatment unit configured to perform heat treatment of the brushed
pile knitted fabrics.
15. The manufacturing machine of claim 14, wherein the cutting unit
includes: at least a knife blade configured to cut the double woven
fabric; at least a grinding stone selectively engaged to the at
least a knife blade to grind the at least a knife blade; driving
pulleys engaged to the at least a knife blade and configured to
position the at least a knife blade; driving belts coupled to the
driving pulleys and configured to rotate the driving pulleys; and a
fixing shaft fixed to the at least a knife blade.
16. The manufacturing machine of claim 14, wherein the at least a
grinding stone is configured to grind the at least a knife blade at
a grinding angle of 45-55.degree..
17. The manufacturing machine of claim 14, wherein each of the
brushing units includes a cylinder and a brush coupled to the
cylinder.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent
Application No. 10-2018-0173372 filed on Dec. 31, 2018, the entire
contents of which is incorporated herein for all purposes by this
reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a pile knit fabric for
internal materials of vehicles which has excellent physical
coupling force between yarns and has excellent abrasion resistance,
scratch resistance and formability as well as soft tactility, a
method of manufacturing the same, and a manufacturing machine of
the pile knitted fabric.
Description of Related Art
[0003] A non-woven fabric or a bulked continuous filament (BCF)
fabric is used as a skin material of luggage trim parts mounted to
cover a vehicle body, wire harnesses, a spare tire, etc. exposed to
the internal to a vehicle trunk and to secure a cargo space. The
conventional non-woven fabric is manufactured through physical
interlacing of fibers using carding and needle-punching processes
and, thus, has low production cost but has insufficient coupling
force between the fibersand causes lowering of abrasion and scratch
performance (defibration). Furthermore, needle-punched marks are
visible on the surface of the fabric and thus marketability of the
fabric is lowered, and only short piles of a loop type are made and
thus tactility of the fabric is insufficient.
[0004] To solve these problems, a BCF fabric, in which yarns are
planted in a base fabric to have a length of 3-10 mm and a latex
layer or a coating layer is applied to the rear surface of the base
fabric to prevent pulling-out of the yarns, is applied. However,
such a manufacturing method in which yarns are planted in a base
fabric lowers fabric elongation and is thus disadvantageous to
forming of a product having a complicated shape. Furthermore, the
BCF fabric manufactured through various processes has higher
production cost than the conventional non-woven fabric and is thus
limitedly used in only floor carpeting in Korea. In addition, there
are no cases that the BCF fabric is applied to luggage trim parts,
and there are some cases that the BCF fabric is applied to luxury
cars only in overseas. Accordingly, research and development of a
new material, which is inexpensive, does not restrict the shapes of
parts and has excellent abrasion resistance and scratch resistance,
has been required.
[0005] The information included in this Background of the present
invention section is only for enhancement of understanding of the
general background of the invention and may not be taken as an
acknowledgement or any form of suggestion that this information
forms the prior art already known to a person skilled in the
art.
BRIEF SUMMARY
[0006] Various aspects of the present invention are directed to
providing a pile knit fabric for internal materials of vehicles
which has excellent physical coupling force between yarns and soft
surface tactility.
[0007] Various aspects of the present invention are directed to
providing a method of manufacturing a pile knit fabric for internal
materials of vehicles in which productivity is enhanced and a
manufacturing process is shortened.
[0008] It is yet another object of the present invention to provide
a manufacturing machine of a pile knit fabric for internal
materials of vehicles.
[0009] Various aspects of the present invention are directed to
providing a pile knit fabric for internal materials of vehicles,
including a knit layer prepared by weaving a plurality of ground
yarns lengthwise and widthwise into loop shapes and a pile layer
prepared by interweaving a plurality of pile yarns with ground yarn
loops of the knit layer, wherein the knit layer is prepared by
weaving the ground yarns to form a double-sided loop structure or a
single-sided loop structure, and the pile layer is fixed to one
surface of the knit layer and prepared by interlacing the pile
yarns with the ground yarn loops of the knit layer.
[0010] In an exemplary embodiment of the present invention, the
ground yarns or the pile yarns may be formed of one or more
selected from the group consisting of polyamide, polypropylene,
polyethylene terephthalate (PET) and wool.
[0011] In another exemplary embodiment of the present invention,
the number of the ground yarn loops of the knit layer may be
250-950 per meter in the horizontal direction thereof.
[0012] In yet another exemplary embodiment, the ground yarns may
have fineness of 50-200 denier.
[0013] In yet another exemplary embodiment, the knit layer may have
a thickness of 0.1-2 mm and a weight per area of 40-200
g/m.sup.2.
[0014] In still yet another exemplary embodiment, one strand of the
pile yarns may include 10-140 strands of filaments, and the
filaments have fineness of 3-25 denier.
[0015] In a further exemplary embodiment, the pile yarns may have a
length of 2-10 mm.
[0016] In another further exemplary embodiment, the pile layer may
have a thickness of 1-9 mm and a weight per area of 100-600
g/m.sup.2.
[0017] In yet another further exemplary embodiment, the pile knit
fabric may have a weight per area of 200-700 g/m.sup.2.
[0018] Various aspects of the present invention are directed to
providing a method of manufacturing a pile knit fabric for internal
materials of vehicles, including preparing a plurality of ground
yarns and a plurality of pile yarns, weaving the ground yarns into
loop shapes to intersect each other lengthwise and widthwise,
producing a double woven fabric using a double Raschel method by
interweaving the pile yarns with ground yarn loops, producing pile
knit fabrics by cutting the pile yarns of the double woven fabric,
brushing the cut pile yarns of the pile knit fabrics, and
performing heat treatment of the brushed pile knit fabrics.
[0019] In an exemplary embodiment of the present invention, in the
producing the pile knit fabrics, the pile yarns of the double woven
fabric may be cut to have a length of 2-10 mm.
[0020] In another exemplary embodiment of the present invention, in
the brushing the pile knit fabrics, the cut pile knit fabrics may
be brushed by rotating a brush at a rate of 400-800 rpm and a speed
of 4-10 m/min
[0021] In yet another exemplary embodiment, in the performing heat
treatment of the pile knit fabrics, the heat treatment may be
performed at a temperature of 110-200.degree. C. for 2-10
minutes.
[0022] It is another object of the present invention to a
manufacturing machine of a pile knit fabric for internal materials
of vehicles, including a weaving unit configured to produce a
double woven fabric by weaving a plurality of ground yarns into
loop shapes to intersect each other lengthwise and widthwise and
connecting ground yarn loops by pile yarns through vertical
reciprocation, fabric transfer rollers configured to transfer the
double woven fabric produced by the weaving unit, a cutting unit
configured to produce pile knit fabrics by cutting the pile yarns
of the double woven fabric transferred from the fabric transfer
rollers, brushing units configured to brush the surfaces of the cut
pile yarns of the pile knit fabrics, and a heat treatment unit
configured to perform heat treatment of the brushed pile knit
fabrics.
[0023] In an exemplary embodiment of the present invention, the
cutting unit may include knife blades configured to cut the double
woven fabric, grinding stones selectively engaged to the knife
blades to grind the knife blades, driving pulleys configured to
position the knife blades, driving belts coupled to the driving
pulleys and configured to rotate the driving pulleys, and a fixing
shaft fixed to the knife blades.
[0024] In another exemplary embodiment of the present invention,
the grinding stones may grind the knife blades at a grinding angle
of 45-55.degree..
[0025] In yet another exemplary embodiment, each of the brushing
units may include a cylinder and a brush coupled to the
cylinder.
[0026] Other aspects and exemplary embodiments of the invention are
discussed infra.
[0027] The above and other features of the invention are discussed
infra.
[0028] The methods and apparatuses of the present invention have
other features and advantages which will be apparent from or are
set forth in more detail in the accompanying drawings, which are
incorporated herein, and the following Detailed Description, which
together serve to explain certain principles of the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1A is a view exemplarily illustrating a knit layer in
accordance with various aspects of the present invention, in which
ground yarns are woven to form a double-sided loop structure;
[0030] FIG. 1B is a photograph of the knit layer in accordance with
various aspects of the present invention, in which the ground yarns
are woven to the double-sided loop structure;
[0031] FIG. 2A is a view exemplarily illustrating a knit layer in
accordance with various aspects of the present invention, in which
ground yarns are woven to form a single-sided loop structure;
[0032] FIG. 2B is a photograph of the knit layer in accordance with
various aspects of the present invention, in which the ground yarns
are woven to form the single-sided loop structure;
[0033] FIG. 3A and FIG. 3B are photographs showing cross-sections
of a pile knit fabric in accordance with various aspects of the
present invention;
[0034] FIG. 4 is a structural view of a manufacturing machine of a
pile knit fabric in accordance with various aspects of the present
invention;
[0035] FIG. 5A and FIG. 5B are photographs showing abrasion test
results of fabrics manufactured in comparative example 1 and
example 2 in accordance with various aspects of the present
invention;
[0036] FIG. 6A, FIG. 6B and FIG. 6C are photographs showing
manufactured fabrics of comparative examples 1 and 2 and example 2
in accordance with various aspects of the present invention;
[0037] FIG. 7A and FIG. 7B are photographs showing evaluation of a
degree of contamination of the manufactured fabric of comparative
example 1 in accordance with various aspects of the present
invention;
[0038] FIG. 8A and FIG. 8B are photographs showing evaluation of a
degree of contamination of the manufactured fabric of example 2 in
accordance with various aspects of the present invention;
[0039] FIG. 9A and FIG. 9B are photographs showing the manufactured
fabrics of comparative example 2 and example 2 in accordance with
various aspects of the present invention; and
[0040] FIG. 10A, FIG. 10B and FIG. 10C are photographs showing
luggage trims formed using the manufactured fabrics of comparative
examples 1 and 2 and example 2 in accordance with various aspects
of the present invention.
[0041] It may be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various features illustrative of the basic
principles of the present invention. The specific design features
of the present invention as included herein, including, for
example, specific dimensions, orientations, locations, and shapes
will be determined in part by the particularly intended application
and use environment.
[0042] In the figures, reference numbers refer to the same or
equivalent parts of the present invention throughout the several
figures of the drawing.
DETAILED DESCRIPTION
[0043] Reference will now be made in detail to various embodiments
of the present invention(s), examples of which are illustrated in
the accompanying drawings and described below. While the present
invention(s) will be described in conjunction with exemplary
embodiments of the present invention, it will be understood that
the present description is not intended to limit the present
invention(s) to those exemplary embodiments. On the contrary, the
present invention(s) is/are intended to cover not only the
exemplary embodiments of the present invention, but also various
alternatives, modifications, equivalents and other embodiments,
which may be included within the spirit and scope of the present
invention as defined by the appended claims.
[0044] Hereinafter reference will be made in detail to various
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings and described below. While
the present invention will be described in conjunction with
exemplary embodiments of the present invention, it will be
understood that the present description is not intended to limit
the present invention to the exemplary embodiments. On the
contrary, the present invention is intended to cover not only the
exemplary embodiments of the present invention, but also various
alternatives, modifications, equivalents and other embodiments
within the spirit and scope of the present invention as defined by
the appended claims.
[0045] In the following description of the embodiments, the same
elements are denoted by the same reference numerals even though
they are depicted in different drawings. In the drawings,
dimensions of structures are exaggerated as compared to actual
dimensions thereof, for clarity of description. In the following
description of the embodiments, terms, such as "first", "second",
etc., may be used to describe various elements but do not limit the
elements. These terms are used only to distinguish one element from
other elements. For example, a first element may be named a second
element and similarly the second element may be named the first
element, within the spirit and scope of the present invention.
Singular expressions may encompass plural expressions, unless they
have clearly different contextual meanings.
[0046] In the following description of the embodiments, terms, such
as "comprising", "including", "having", etc., will be interpreted
as indicating the presence of characteristics, numbers, steps,
operations, elements or parts stated in the description or
combinations thereof, and do not exclude the presence of one or
more other characteristics, numbers, steps, operations, elements,
parts or combinations thereof, or possibility of adding the same.
In addition, it will be understood that, when a part, such as a
layer, a film, a region or a plate, is said to be "on" another
part, the part may be located "directly on" the other part or other
parts may be interposed between both parts. In the same manner, it
will be understood that, when a part, such as a layer, a film, a
region or a plate, is said to be "under" another part, the part may
be located "directly under" the other part or other parts may be
interposed between both parts.
[0047] All numbers, values and/or expressions representing
components, reaction conditions, polymer compositions and amounts
of blends used in the description are approximations in which
various uncertainties in measurement generated when these values
are acquired from essentially different things are reflected and
thus, it will be understood that they are modified by the term
"about", unless stated otherwise. In addition, it will be
understood that, if a numerical range is included in the
description, such a range includes all continuous values from a
minimum value to a maximum value of the range, unless stated
otherwise. Furthermore, if such a range refers to integers, the
range includes all integers from a minimum integer to a maximum
integer of the range, unless stated otherwise.
[0048] In the following description of the embodiments, it will be
understood that, when a range of variables is stated, the variables
include all values within the stated range including stated end
points of the range. For example, it will be understood that a
range of "5 to 10" not only includes values of 5, 6, 7, 8, 9 and 10
but also includes arbitrary subranges, such as a subrange of 6 to
10, a subrange of 7 to 10, a subrange of 6 to 9, a subrange of 7 to
9, etc. and arbitrary values between integers which are valid
within the scope of the stated range, such as 5.5, 6.5, 7.5, 5.5 to
8.5, 6.5 to 9, etc. Furthermore, for example, it will be understood
that a range of "10% to 30%" not only includes all integers
including values of 10%, 11%, 12%, 13%, . . . 30% but also includes
arbitrary subranges, such as a subrange of 10% to 15%, a subrange
of 12% to 18%, a subrange of 20% to 30%, etc., and arbitrary values
between integers which are valid within the scope of the stated
range, such as 10.5%, 15.5%, 25.5%, etc.
[0049] In general, a non-woven fabric is manufactured by measuring
PET fibers or PA fibers and forming physical interlacing through
carding, stacking and needle-punching processes. As described
above, the non-woven fabric has a higher production speed than
other fabrics and may thus have low production cost, and is
manufactured through physical interlacing of fibers and may thus
have excellent bidirectional elongation and implement various
shapes during forming of a product. However, the conventional
non-woven fabric has insufficient coupling force between the fibers
due to physical interlacing and may thus be weak to abrasion or
scratch, and cause dust due to generation of a large number of
short fibers during the needle-punching process. Furthermore,
needle-punched marks remain on the surface of the fabric and are
thus transferred to the product.
[0050] In contrast, a BCF fabric is manufactured by planting yarns
in a base fabric and coating the rear surface of the base fabric
with latex and has excellent abrasion and scratch performance
because the yarns planted in the base fabric are attached to latex.
Furthermore, the yarns are oriented in a vertical direction based
on the base fabric and thus, the BCF fabric has an excellent
texture. However, since the yarns are planted in the base fabric
and the rear surface of the base fabric is coated with latex, the
BCF fabric has poor elongation during forming of a product and thus
limits the shape of the product. Furthermore, the BCF fabric is
manufactured through a complicated manufacturing process and thus
has high production cost and is limitedly applied only to
carpeting.
[0051] To solve these problems, in an exemplary embodiment of the
present invention, a pile knit fabric, including a knit layer
prepared by weaving ground yarns and a pile layer prepared by
interweaving pile yarns with ground yarn loops of the knit layer,
is manufactured, and thus excellent physical coupling force between
the ground yarns may be acquired and tactility may be enhanced due
to excellent fiber orientation of the pile yarns. Furthermore, the
pile knit fabric has excellent abrasion resistance and scratch
resistance and has excellent formability and may thus implement
various shapes during forming of a product. In addition, since two
pile knit fabrics are manufactured by cutting the centers of pile
yarns of a double woven fabric, productivity may be improved and a
manufacturing process may be shortened because separate latex
treatment on the rear surface of the fabric, which was conducted on
the conventional BCF or non-woven fabric, is not necessary.
[0052] In addition, in a manufacturing machine of a pile knit
fabric, including a grinding unit to grind a knife blade at a
designated angle, the knife blade may be ground simultaneously with
cutting of pile yarns. Furthermore, the angle of grinding stones
may be adjusted according to fineness of the pile yarns, thus
grinding the knife blade sharply.
[0053] Hereinafter, a pile knit fabric for internal materials of
vehicles, a method of manufacturing the same, and a manufacturing
machine of the pile knit fabric in accordance with various aspects
of the present invention will be described in detail with reference
to the accompanying drawings
[0054] Various aspects of the present invention are directed to
providing a pile knit fabric for internal materials of vehicles,
including a knit layer prepared by weaving a plurality of ground
yarns lengthwise and widthwise into loop shapes and a pile layer
prepared by interweaving a plurality of pile yarns with ground yarn
loops of the knit layer, the knit layer being prepared by weaving
the ground yarns to form a double-sided loop structure or a
single-sided loop structure, and the pile layer being fixed to one
surface of the knit layer and being prepared by interlacing the
pile yarns with the ground yarn loops of the knit layer.
[0055] FIG. 1A is a view exemplarily illustrating a knit layer in
accordance with various aspects of the present invention, in which
ground yarns are woven to form a double-sided loop structure.
Furthermore, FIG. 1B is a photograph of the knit layer in
accordance with various aspects of the present invention, in which
the ground yarns are woven to form the double-sided loop structure.
When the ground yarns are woven to form the double-sided loop
structure, the knit layer may be firmly woven, the pile yarns may
be firmly fixed to loops of the ground yarns, and soft tactility of
the surface of the pile knit fabric may be realized.
[0056] The loop shape may be circular or elliptical, and may be a
polygon such as a square, a rectangle, a pentagon, or a
hexagon.
[0057] FIG. 2A is a view exemplarily illustrating a knit layer in
accordance with various aspects of the present invention, in which
ground yarns are woven to form a single-sided loop structure.
Furthermore, FIG. 2B is a photograph of the knit layer in
accordance with various aspects of the present invention in which
the ground yarns are woven to form the single-sided loop structure.
When the ground yarns are woven to form the single-sided loop
structure, elongation of the knit layer may be enhanced and
simultaneously an excellent feeling of cushion of the pile knit
fabric may be secured.
[0058] The ground yarns or the pile yarns are yarns to weave
fabrics. The ground yarns mean yarns forming a woven bottom surface
of the pile knit fabric. The pile yarns mean soft yarns covering
the surface of the woven knit layer.
[0059] FIG. 3A and FIG. 3B are photographs showing cross-sections
of the pile knit fabric in accordance with various aspects of the
present invention. FIG. 3(a) shows the pile layer prepared by
interweaving the pile yarns with the loops of the ground yarns, and
FIG. 3(b) shows the knit layer prepared by weaving a plurality of
ground yarns. Therethrough, it may be understood that the knit
layer and the pile layer are woven tightly and physical coupling
force therebetween is excellent.
[0060] The ground yarns or the pile yarns may be formed of one or
more selected from the group consisting of polyamide,
polypropylene, polyethylene terephthalate (PET), wool and
combination thereof.
[0061] The number of the ground yarn loops of the knit layer is
250-950 per meter in the horizontal direction thereof. Here, when
the number of the ground yarn loops is less than 250 per meter, an
interval between the pile yarns of the pile layer is excessively
broad and, thus, a fabric structure is not properly formed. On the
other hand, when the number of ground yarn loops exceeds 950 per
meter, the interval between the pile yarns of the pile layer is
excessively narrow and weaving is impossible.
[0062] The knit layer is formed of the ground yarns, and fineness
of the ground yarns may be 50-200 denier (D). When the fineness of
the ground yarns is less than 50 denier, the ground yarns are weak
and thus strength of the manufactured pile knit fabric may be
lowered. On the other hand, when the fineness of the ground yarns
exceeds 200 denier, production cost is raised and the ground yarns
are thicker than an interval between needles of the manufacturing
machine and thus the pile knit fabric may not be properly
manufactured. The fineness of the ground yarns may be 100-150
denier.
[0063] The knit layer may have a thickness of 0.1-2 mm and a weight
per area of 40-200 g/m.sup.2. When the thickness of the knit layer
is less than 0.1 mm, the knit layer is too weak and thus rigidity
of the pile knit fabric may be lowered and, when the thickness of
the knit layer exceeds 2 mm, production cost is raised and a fabric
structure is too hardened and thus the pile knit fabric maybe
unfavorable for forming a product. Furthermore, when the weight per
area of the knit layer is less than 40 g/m.sup.2, the pile knit
fabric is woven loosely and thus rigidity of the pile knit fabric
may be lowered. On the other hand, when the weight per area of the
knit layer exceeds 200 g/m.sup.2, the pile knit fabric is woven
tightly and thus rigidity of the pile knit fabric may be enhanced,
but production cost is raised, the weight of the pile knit fabric
is increased, elongation of the pile knit fabric is lowered due to
hardening of the fabric structure and thus the pile knit fabric may
be unfavorable for forming a product. The weight per area of the
knit layer may be 70-100 g/m.sup.2.
[0064] One strand of the pile yarns includes 10-140 strands of
filaments, and the filaments may have fineness of 3-25 denier.
Here, when the number of the strands of the filaments included in
one strand of the pile yarns is less than 10, the surface of the
pile knit fabric is tough and thus soft tactility of the pile knit
fabric may not be achieved. On the other hand, when the number of
the strands of the filaments included in one strand of the pile
yarns exceeds 140, the fineness of the pile yarns is excessively
low and thus abrasion resistance of the surface of the pile knit
fabric may be lowered. Particularly, one strand of the pile yarns
may include 10-50 strands of the filaments. More particularly, one
strand of the pile yarns may include 10-30 strands of the
filaments.
[0065] Furthermore, when the fineness of the filaments is less than
3 denier, the fineness of the pile yarns is excessively low and
thus abrasion resistance of the surface of the pile knit fabric may
be lowered. On the other hand, when the fineness of the filaments
exceeds 25 denier, the surface of the pile knit fabric is tough and
thus soft tactility may not be achieved. The fineness of the
filaments may be particularly 5-17 denier and more particularly
7-10 denier.
[0066] To implement an excellent feeling of cushion and soft
tactility of the pile layer, the pile yarns may have a length of
2-10 mm. When the length of the pile yarns is less than 2 mm, the
pile yarns are too short, the surface of the pile layer is tough
and thus tactility may be lowered. On the other hand, when the
length of the pile yarns exceeds 10 mm, abrasion resistance is low,
a touch imprint may occur and increase in the weight of the pile
knit fabric may be caused. The length of the pile yarns may be 3-5
mm.
[0067] The pile layer may have a thickness of 1-9 mm and a weight
per area of 100-600 g/m.sup.2. When the thickness of the pile layer
is less than 1 mm, the pile knit fabric may not exhibit an
excellent feeling of cushion and, when the thickness of the pile
layer exceeds 9 mm, the weight of the pile knit fabric is increased
and thus the total weight of a part manufactured using the pile
knit fabric may be increased and production cost may be excessively
raised. Furthermore, when the weight per area of the pile layer is
less than 100 g/m.sup.2, a feeling of cushion of the pile knit
fabric may not be implemented and abrasion resistance of the pile
knit fabric may be lowered. On the other hand, when the weight per
area of the pile layer exceeds 600 g/m.sup.2, fuel efficiency may
be lowered due to increase in the total weight of the part and
production cost may be excessively raised.
[0068] The pile knit fabric may have a weight per area of 200-700
g/m.sup.2. When the weight per area of the pile knit fabric is less
than 200 g/m.sup.2, a fabric surface layer is not sufficiently
formed and thus abrasion resistance of the surface of the pile knit
fabric may be lowered. On the other hand, when the weight per area
of the pile knit fabric exceeds 700 g/m.sup.2, production cost may
be raised and fuel efficiency may be lowered due to increase in the
total weight of the part. The weight per area of the pile knit
fabric may be particularly 260-370 g/m.sup.2 and more particularly
320-360 g/m.sup.2.
[0069] Furthermore, various aspects of the present invention are
directed to providing a method of manufacturing a pile knit fabric
for internal materials of vehicles, including preparing a plurality
of ground yarns and a plurality of pile yarns, weaving the ground
yarns into loop shapes to intersect each other lengthwise and
widthwise, producing a double woven fabric using a double Raschel
method by interweaving the pile yarns with ground yarn loops,
producing pile knitted fabrics by cutting the pile yarns of the
double woven fabric, brushing the cut pile yarns of the pile
knitted fabrics, and performing heat treatment of the brushed pile
knitted fabrics.
[0070] In preparing the ground yarns and the pile yarns, yarns to
manufacture the pile knit fabric may be prepared. The ground yarns
or the pile yarns may be formed of one or more selected from the
group consisting of polyamide, polypropylene, polyethylene
terephthalate (PET), wool and combination thereof.
[0071] In weaving the ground yarns, the ground yarns may be woven
to form the double-sided loop structure, as exemplarily shown in
FIG. 1A and FIG. 1B. Furthermore, the ground yarns may be woven to
form the single-sided loop structure, as exemplarily shown in FIG.
2A and FIG. 2B.
[0072] In producing the double woven fabric, the double woven
fabric, in which the pile yarns are connected between two knit
layers prepared by weaving the ground yarns using the double
Raschel method, may be produced. Here, the pile yarns may
vertically reciprocate and thus be interwoven with the respective
loops of the ground yarns.
[0073] In producing the pile knitted fabrics, the pile yarns of the
double woven fabric may be cut to have a length of 2-10 mm. In
producing the pile knitted fabrics, the pile yarns may be cut to
have the length of 2-10 mm in consideration of a feeling of cushion
and tactility of the pile knitted fabrics. That is, when the length
of the pile yarns is 2-10 mm, the pile knit fabric may have an
excellent feeling of cushion and soft tactility while maintaining
required rigidity.
[0074] Furthermore, in producing the pile knitted fabrics, two pile
knitted fabrics may be simultaneously produced by cutting the pile
yarns located between both sides of the double woven fabric. Such a
method may improve productivity by about 1.7 times or more, as
compared to a conventional method of manufacturing a fabric just by
weaving one side thereof.
[0075] In brushing the pile knitted fabrics, the cut pile knitted
fabrics may be brushed by rotating a brush at a rate of 400-800 rpm
and a speed of 4-10 m/min. In brushing the pile knitted fabrics,
the cut pile yarns of the pile knitted fabrics are disposed with
the brush so that fiber orientation is uniformized and, thus,
tactility and a feeling of cushion of the pile yarns may be
enhanced.
[0076] In performing heat treatment of the pile knitted fabrics,
heat treatment may be performed at a temperature of 110-200.degree.
C. for 2-10 minutes. Here, when the temperature of heat treatment
is lower than 110.degree. C., uniformity in thermosetting of the
surface of the pile layer is lowered and, thus, a deviation in
appearance in the surface of the pile knit fabric may occur. On the
other hand, when the temperature of heat treatment exceeds
200.degree. C., some of the pile yarns of the pile layer are
damaged by heat and thus tactility may be lowered.
[0077] Various aspects of the present invention are directed to
providing a formed product for internal materials of vehicles using
the pile knitted fabric. The formed product for internal materials
of vehicles may be a luggage trim. The formed product for internal
materials of vehicles may be manufactured by preheating a base
material, stacking the preheated base material and the pile knit
fabric within a cooling mold and then performing press forming. In
the instant case, since only the base material is preheated and
then the base material and the pile knit fabric are pressed, the
pile yarns of the pile knit fabric are scarcely damaged during
forming and, thus, the formed product for internal materials of
vehicles may have excellent tactility and a fine appearance.
[0078] Furthermore, various aspects of the present invention are
directed to providing a manufacturing machine 100 of a pile knit
fabric 60 for internal materials of vehicles, including a weaving
unit 10 configured to produce a double woven fabric 11 by weaving a
plurality of ground yarns into loop shapes to intersect each other
lengthwise and width wise and connecting ground yarn loops by pile
yarns through vertical reciprocation, fabric transfer rollers 20,
30 and 70 configured to transfer the double woven fabric 11
produced by the weaving unit 10, a cutting unit 50 configured to
produce pile knitted fabrics 60 by cutting the pile yarns of the
double woven fabric 11 transferred from the fabric transfer rollers
20 and 30, brushing units 80 configured to brush the surfaces of
the cut pile yarns of the pile knitted fabrics 60, and a heat
treatment unit configured to perform heat treatment of the brushed
pile knitted fabrics 60.
[0079] FIG. 4 is a structural view of the manufacturing machine 100
of the pile knit fabric 60 in accordance with various aspects of
the present invention. Referring to FIG. 4, the double woven fabric
11 produced by the weaving unit 10 is transferred to the cutting
unit 50 by the fabric transfer rollers 20 and 30. The cutting unit
50 cuts the double woven fabric 11 into the pile knitted fabrics 60
using a knife blade 40, and the pile knitted fabrics 60 are
transferred by the fabric transfer rollers 70 located at both sides
of the cutting unit 50. The pile knitted fabrics 60 are transferred
to the brushing units 80 to brush the surfaces of the pile
yarns.
[0080] The cutting unit 50 may include knife blades 40 configured
to cut the double woven fabric 11, grinding stones 53 configured to
grind the knife blades 40, driving pulleys 51 configured to
position the knife blades 40, driving belts 52 configured to rotate
the driving pulleys 51, and a fixing shaft 54 configured to fix the
knife blades 40.
[0081] The lengths of the cut pile yarns may be adjusted by
adjusting the position of the knife blade 40. That is, two pile
knitted fabrics having the same length of the pile yarns or two
pile knit fabric having different lengths of the pile yarns may be
manufactured. Furthermore, a process of grinding the knife blade 40
may be performed after or simultaneously with cutting of the double
woven fabric 11. Here, grinding means grinding of the tip portion
of the knife blade 40 to uniformly cut fabrics for a long time.
[0082] The grinding stones 53 is configured to grind the knife
blade 40 which is dulled by cutting fabrics through continuous
processing. Here, the grinding stones 53 may grind the knife blade
40 at a grinding angle of 45-55.degree.. The grinding angle may be
adjusted according to the fineness of the filaments of the pile
yarns. The grinding angle is an angle .alpha. which is measured
from a horizontal line under the grinding stones 53 and may be
suitable to cutting of the filaments having fineness of 3-25
denier. When the grinding angle of the knife blade 40 is less than
45.degree., grinding of the knife blade 40 is insufficient and,
thus, the surface of the pile layer of the pile knit fabric become
irregular and a defect may occur. In contrast, when the grinding
angle of the knife blade 40 exceeds 55.degree., the knife blade 40
is excessively ground and thus abrasion of the knife blade 40 may
occur. Furthermore, the knife blade 40 is frequently replaced due
to excessive grinding, and thus, productivity may be lowered and
there may be a strong possibility that poor quality is caused. The
grinding angle may be adjusted by controlling two grinding stones
51 to contact each other at right angles at a grinding position of
the knife blade 40. In the cutting unit 50, as the knife blade 40
is rotated by the driving pulley 51 and the driving belt 52, a
quality level of the pile knitted fabrics 60 may be determined
according to the feed speed of the double woven fabric 11 and the
grinding angle of the knife blade 40.
[0083] In an exemplary embodiment of the present invention, the
knife blade 40 is provided in plural and each of plurality of knife
blades 40 are selectively engaged to the grinding stones 53.
[0084] The brushing unit 80 may include a cylinder and a brush
coupled to the cylinder. The brushing unit 80 may brush the
surfaces of the pile yarns of the pile knit fabric 60, produced by
the cutting unit 50, with the brush to uniformly arrange the pile
yarns.
[0085] A conventional fabric manufacturing machine has a weaving
speed of about 15 m per hour, but the manufacturing machine 100 in
accordance with various aspects of the present invention may weave
about 90 m of the pile knit fabric 60 per hour. Furthermore, in the
conventional fabric manufacturing machine, it takes 67 hours to
manufacture about 1,000 m of the pile knit fabric 60. On the other
hand, the manufacturing machine 100 in accordance with various
aspects of the present invention may weave the double woven fabric
11 for 39 hours and perform cutting of the double woven fabric 11
into the pile knitted fabrics 60 for 6 hours and, thus, require
total 45 hours. Therefore, the manufacturing machine 100 in
accordance with various aspects of the present invention may
enhance productivity by about 1.7 times, as compared to the
conventional method of manufacturing a fabric just by weaving one
side thereof.
[0086] Hereinafter, the present invention will be described in more
detail through the following examples. The following examples are
only for enhancement of understanding of the present invention and
are not intended to limit the scope of the present invention.
Example 1
[0087] As stated in Table 1 below, PET yarns having fineness of 100
D were prepared as ground yarns, 10-20 strands of filaments were
used to prepare one strand of pile yarns, and PET yarns having
fineness of 10D were used as the filaments. The PET ground yarns
were fed to the weaving unit of the manufacturing machine and were
woven to intersect each other lengthwise and widthwise into loop
shapes. Thereafter, a double woven fabric, both sides of which were
woven, was produced by vertically reciprocating the PET pile yarns
at intervals of 4 mm to be interwoven with the loops of the ground
yarns by a knit method. Thereafter, the double woven fabric was
move to the cutting unit by the fabric transfer rollers.
Thereafter, the double woven fabric was divided into pile knitted
fabrics by cutting the centers of the pile yarns of the double
woven fabric using the knife blade of the cutting unit. The
grinding angle of the grinding stones to grind the knife blade was
adjusted to 50.degree.. The knit layer of the pile knit fabric had
a thickness of 1 mm and a weight per area of 100 g/m.sup.2, and the
pile layer has a thickness of 3 mm and a weight per area of 150
g/m.sup.2.
[0088] The cut pile yarns of the pile knit fabric were brushed with
the brush. Here, the brush was rotated at a rate of 600 rpm and a
speed of 6 m/min. Thereafter, the brushed pile knit fabric was
heat-treated at a temperature of 170.degree. C. for 4 minutes.
Examples 2-5
[0089] Pile knitted fabrics were manufactured using the same method
as in example 1, but the details of pile yarns and ground yarns of
the pile knitted fabrics of examples 2-5 were changed as stated in
Table 1.
Comparative Example 1
[0090] A non-woven fabric woven from PET yarns having fineness of
10 D was prepared.
Comparative Example 2
[0091] A bulked continuous filament (BCF) fabric woven from PA6
yarns having fineness of 10 D planted in a PET base fabric was
prepared.
Comparative Example 3
[0092] A bulked continuous filament (BCF) fabric woven from PET
yarns having fineness of 10 D planted in a PET base fabric was
prepared.
TABLE-US-00001 TABLE 1 Pile layer (pile yarn) Knit layer (ground
yarn) Filament Weight Length of Weight fineness per area pile yarn
Fineness per area Classification Component (D) (g/m.sup.2) (mm)
Component (D) (g/m.sup.2) Example 1 PET 10 150 2 PET 100 100
Example 2 PET 7 250 3 PET 100 100 Example 3 PET 10 250 3 PET 100
100 Example 4 PET 10 270 5 PET 100 110 Example 5 PA6 10 250 3 PET
100 100 Comparative PET non- 10 450 3 example 1 woven fabric
Comparative PA6 10 300 5 PET base fabric 100 example 2 Comparative
PET 10 300 5 PET base fabric 100 example 3
Test Example 1
[0093] To evaluate properties of the manufactured fabrics of
examples 1-5 and comparative examples 1-3, the properties of the
respective fabrics were measured using the following methods.
Results of evaluation will be stated and shown in Table 2 and FIG.
5A and FIG. 5B.
[0094] [Evaluation Methods]
[0095] Evaluation of Basic Properties of Fabrics
[0096] Weight per area: Three specimens of each of the fabrics,
having a width 250 mm and a length 250 mm, were prepared, weights
of the specimens were measured to .+-.0.01 g, and an average of the
three measured weights was determined and stated as a weight per
area (unit: g/m.sup.2).
[0097] Tensile strength: Specimens of the fabrics, having a width
of 50 mm and a length of 250 mm, were pulled at a speed of 200
m/min using a universal testing machine (UTM) and thus maximum
loads were measured.
[0098] Elongation: Specimens of the fabrics, having a width of 50
mm and a length of 250 mm, were pulled at a speed of 200 m/min
using the UTM and thus elongations when the specimens fractured
were measured.
[0099] Emotional Quality Evaluation
[0100] Abrasion: After the fabrics underwent an abrasion test using
an abrasion tester from TABER industries, in which the number of
rotations is set to 100, a load is set to 1 kg and an H-18 abrasion
wheel is used, states of the fabrics were determined as the below
grades.
[0101] Grade 1: Cut and wear of a pile layer are severe and a worn
surface is severely hollowed out.
[0102] Grade 2: Cut and wear of a pile layer and pulling-up of pile
yarns are clearly visible.
[0103] Grade 3: Cut and wear of a pile layer slightly occur but are
invisible.
[0104] Grade 4: Cut of a pile layer slightly occurs.
[0105] Grade 5: No wear of a pile layer is confirmed.
[0106] Tactility: The textures of the fabrics felt by hand are
classified into reference values (5: favorable 1: unfavorable,
favorable meaning soft and unfavorable meaning tough).
TABLE-US-00002 TABLE 2 Properties Composition Length of Weight
Tensile Pile Ground pile yarn per area strength Elongation Abrasion
Production Classification yarn yarn (mm) (g/m.sup.2) (N/50 mm) (%)
(grade) tactility cost Example 1 PET PET 2 250 385 80 3 4 1 Example
2 PET PET 3 350 400 80 3 5 1.1 Example 3 PET PET 3 350 400 80 3 4-5
1.15 Example 4 PET PET 5 380 440 80 3 5 1.4 Example 5 PA6 PET 3 350
400 80 3 4 1.3 Comparative PET (non- 3 450 300 60 2 2 1 example 1
woven fabric) Comparative PA6 (base 5 400 380 40 3-4 3 2 example 2
fabric: PET) Comparative PET (base 5 400 380 30 3 3 1.6 example 3
fabric: PET)
[0107] The results of Table 2 show that the fabrics of examples 1
to 5 have lower weights per area than the fabrics of comparative
examples 1 to 3 but have higher tensile strengths than the fabrics
of comparative examples 1 to 3. Furthermore, it was confirmed that
the fabrics of examples 1 to 5 not only have exhibit elongation of
80% but also exhibit enhanced abrasion grades and tactility.
However, it was confirmed that, if the length of the pile yarns is
long or PA6 yarns and PET yarns are mixed as in the fabrics of
examples 4 and 5, production cost is slightly increased but such an
increase is lower than that of the fabric of comparative example
2.
[0108] In contrast, it was confirmed that the conventional PET
non-woven fabric of comparative example 1 has low production cost
but has a heavy weight per area and low tensile strength. Due to
the low tensile strength, needle-punched marks at a bent portion
were exposed after forming a product and, thus, quality of the
product was lowered. Furthermore, the fabric of comparative example
1 exhibits poor properties, i.e., low elongation, a low abrasion
grade and poor tactility.
[0109] Furthermore, it was confirmed that the fabrics of
comparative examples 2 and 3 have heavy weights per area due to use
of the base fabric and are thus difficult to exhibit a lightweight
effect, and they exhibit high tensile strengths but the tensile
strengths thereof are lower than the tensile strengths of the
fabrics of examples 1-5. Furthermore, it was confirmed that the
fabrics of comparative examples 2 and 3 have the highest production
costs.
[0110] FIG. 5A and FIG. 5B are photographs showing abrasion test
results of the fabrics manufactured in comparative example 1 and
example 2. FIG. 5A shows that the fabric of comparative example 1
generated a lot of lint and cut of the pile yarns after the
abrasion test. In contrast, FIG. 5B shows that the fabric of
example 2 did not generate lint or cut of the pile yarns after the
abrasion test but maintained a soft surface texture.
Test Example 2: Evaluation of Properties of Formed Products
According Fabric Types
[0111] Luggage trims were manufactured using the fabrics of example
2 and comparative examples 1 and 2. Appearances and contamination
degrees of the manufactured luggage trims were evaluated, and
results of such evaluation will be stated and shown in Table 3 and
FIGS. 6(a) to 10(c).
[0112] [Evaluation Method]
[0113] Appearance and contamination degree: After 20 g of sand was
sprinkled over the fabrics (200.times.200 mm) and then the fabrics
are put into the mold to manufacture luggage trims, the
manufactured luggage trims were cleaned by reciprocating a portable
handheld cleaner for vehicles one time and then sand remaining
amounts on the formed products were verified with the naked eye.
Results of evaluation are represented by several marks
(.circle-w/dot.: very good, .largecircle.: good, .DELTA.: bad, and
x: very bad).
[0114] The results of Table 3 show that a bent portion of the
luggage trim manufactured using the fabric of example 2 is not
exposed and thus the appearance of the luggage trim is very good,
and the luggage trim exhibits soft tactility. Furthermore, it was
confirmed that, in the contamination test, contaminants are easily
removed from the luggage trim, and the fabric has a lighter weight
of 350 g/m.sup.2 than those of the fabrics of comparative examples
1 and 2.
[0115] In contrast, it was confirmed that the luggage trim
manufactured using the fabric of comparative example 1 has a low
density at a bent portion and thus the appearance of the luggage
trim is bad, and the luggage trim exhibits low or poor values of
properties, i.e., poor tactility, a low contamination degree and a
heavy weight per area.
[0116] Furthermore, it was confirmed that a weaving pattern at some
parts of the luggage trim manufactured using the fabric of
comparative example 2 is externally exposed and thus the appearance
of the luggage trim is not very good, and the luggage trim exhibits
low or poor values of properties, i.e., poor tactility, a low
contamination degree and a heavy weight per area, as compared to
the luggage trim manufactured using the fabric of example 2.
[0117] FIG. 6A, FIG. 6B and FIG. 6C are photographs showing the
manufactured fabrics of comparative examples 1 and 2 and example 2.
FIG. 6A, FIG. 6B and FIG. 6C show that the pile yarns of the pile
knit fabric of example 2 are more densely disposed than the yarns
of the fabrics of comparative examples 1 and 2.
[0118] FIG. 7A and FIG. 7B are photographs showing evaluation of a
degree of contamination of the manufactured fabric in comparative
example 1. FIG. 7A and FIG. 7B show that foreign substances, such
as sand, enter spaces between irregular pile yarns on the surface
of the low-density non-woven fabric and thus it is difficult to
remove the foreign substances.
[0119] FIG. 8A and FIG. 8B are photographs showing evaluation of a
degree of contamination of the manufactured fabric in example 2.
FIG. 8A and FIG. 8B show that the pile knit fabric of example 2 is
woven at a relatively high density, as compared to the fabric of
comparative example 1, and thus foreign substances, such as sand,
remain only on the surface of the pile yarns and are easily
removed.
[0120] FIG. 9A and FIG. 9B are photographs showing the manufactured
fabric of comparative example 2 and the manufactured fabric of
example 2, respectively. FIG. 9A and FIG. 9B show that the pile
knit fabric of example 2 has soft tactility and luxurious
appearance, as compared to the fabric of comparative example 2.
[0121] FIG. 10A, FIG. 10B and FIG. 10C are photographs showing
luggage trims formed using the manufactured fabrics of comparative
examples 1 and 2 and the pile knit fabric of example 2. FIG. 10(a)
shows that, in the case of the luggage trim manufactured using the
non-woven fabric of comparative example 1, the non-woven fabric is
split at a bent portion and the base material is externally exposed
therethrough, and thus quality of the luggage trim is lowered.
Also, FIG. 10(b) shows that, in the case of the luggage trim
manufactured using the fabric of comparative example 2, a weaving
pattern on the base fabric is partially exposed and thus appearance
of the luggage trim is poor.
[0122] In contrast, FIG. 10(c) shows that the luggage trim
manufactured using the pile knit fabric of example 2 has good and
luxurious appearance. Furthermore, it may be confirmed that the
luggage trim manufactured using the pile knit fabric of example 2
has excellent surface tactility and enhanced emotional quality.
[0123] As is apparent from the above description, a pile knit
fabric for internal materials of vehicles in accordance with
various aspects of the present invention, which includes a knit
layer prepared by weaving ground yarns and a pile layer prepared by
interweaving pile yarns with ground yarn loops of the knit layer,
has excellent physical coupling force between the ground yarns and
the pile yarns and uniform fiber orientation of the pile yarns and
may thus improve tactility.
[0124] In addition, the pile knit fabric in accordance with various
aspects of the present invention has excellent abrasion resistance
and scratch resistance and enhanced formability, thus facilitating
realization of products of various shapes.
[0125] Furthermore, a method of manufacturing a pile knit fabric
for internal materials of vehicles in accordance with various
aspects of the present invention, in which the pile knit fabric is
manufactured by producing a double woven fabric and then cutting
the centers of pile yarns of the double woven fabric, improves
productivity and omits separate latex treatment on the rear surface
of the pile knit fabric which was conducted on a conventional BCF
or non-woven fabric, thus shortening a manufacturing process.
[0126] For convenience in explanation and accurate definition in
the appended claims, the terms "upper", "lower", "inner", "outer",
"up", "down", "upper", "lower", "upwards", "downwards", "front",
"rear", "back", "inside", "outside", "inwardly", "outwardly",
"internal", "external", "inner", "outer", "forwards", and
"backwards" are used to describe features of the exemplary
embodiments with reference to the positions of such features as
displayed in the figures.
[0127] It will be further understood that the term "connect" or its
derivatives refer both to direct and indirect connection.
[0128] The foregoing descriptions of specific exemplary embodiments
of the present invention have been presented for purposes of
illustration and description. They are not intended to be
exhaustive or to limit the present invention to the precise forms
disclosed, and obviously many modifications and variations are
possible in light of the above teachings. The exemplary embodiments
were chosen and described to explain certain principles of the
present invention and their practical application, to enable others
skilled in the art to make and utilize various exemplary
embodiments of the present invention, as well as various
alternatives and modifications thereof. It is intended that the
scope of the present invention be defined by the Claims appended
hereto and their equivalents.
* * * * *