Three-dimensional knitted fabric and vehicle interior material including the same

Abstract

Provided are: a three-dimensional knitted fabric that is inhibited from collapsing due to excessive elongation when a tensile load is applied during seat installation, etc., and that has Taber abrasion resistance and scratch resistance according to ASTM; and a vehicle interior material that includes the three-dimensional knitted fabric. The present invention relates to a three-dimensional knitted fabric including a front layer knitted fabric, a back layer knitted fabric, and a connecting thread that connects the front layer knitted fabric and the back layer knitted fabric, the three-dimensional knitted fabric characterized in that the front layer knitted fabric includes a front surface layer positioned on the outermost side of the three-dimensional knitted fabric and a shape-fixing layer that is positioned farther inward in the three-dimensional knitted fabric than the front surface layer and that includes knit loops formed at the same positions as knit loops included in the front surface layer, the knitted fabric density after finishing is 30 to 64 courses / inch inclusive, and the ratio (A) of the number of knit loops included in the front surface layer to the number of knit loops included in the shape-fixing layer is more than 80% and 100% or less. The present invention also relates to a vehicle interior material that includes said three-dimensional knitted fabric.

Description

[Technical Field]

[0001] The present invention relates to a three-dimensional knitted fabric and a vehicle interior material including the same. [Background technology]

[0002] Conventionally, three-dimensional knitted fabrics composed of two layers of knitted fabric, one on the front side and one on the back side, and a connecting yarn connecting the two layers of knitted fabric have cushioning properties in the thickness direction by using monofilament as the connecting yarn, and furthermore, by making the knitted fabrics on the front and back sides into a mesh structure, high breathability is ensured, and they are widely used in applications such as seat covers and bedding as a cushioning material that is cool and prevents stuffiness.

[0003] Patent Document 1 below discloses that a skin material made of a three-dimensional knit fabric, in which the outer surface of the knitted surface layer is the surface that comes into contact with the human body and the stitch density of the surface layer is 11,500 or more and 20,000 or less, can suppress pilling even when the surface is rubbed by the hook part of a hook-and-loop fastener.

[0004] Furthermore, Patent Document 2 below discloses that in a three-dimensional knitted fabric having at least one mesh surface, reinforcing threads are woven into the openings of the mesh to stabilize the shape of the mesh. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2022 / 202815 [Patent Document 2] International Publication No. 2007 / 097363 Summary of the Invention [Problem to be solved by the invention]

[0006] However, although the three-dimensional knitted fabric described in Patent Document 1 has a dense knitted surface, which makes it durable against the irritation of rubbing the surface with hard protrusions such as hooks of a hook-and-loop fastener (hereinafter also referred to as "scratch resistance") and has good Taber abrasion resistance according to the JASO M403A method, it does not take into consideration the ASTM D3884-09 method, which specifies even harsher conditions, or pattern distortion due to stretching of the knitted fabric. Furthermore, although the three-dimensional knitted fabric described in Patent Document 2 has reinforcing yarn woven into the openings of the mesh fabric, thereby improving the stability of the mesh configuration, no consideration was given to scratch resistance, Taber abrasion resistance, or pattern (stitch) collapse due to stretching of the knitted fabric.

[0007] In view of the above-mentioned state of the prior art, the problem to be solved by the present invention is to solve the problems of the above-mentioned prior art and to provide a three-dimensional knitted fabric that has a good feel in a three-dimensional knitted fabric, suppresses stitch collapse due to excessive elongation when a tensile load is applied, such as when a seat is installed, and has Taber abrasion resistance and scratch resistance according to the ASTM method, and a vehicle interior material containing the same. [Means for solving the problem]

[0008] As a result of extensive research and experimentation to solve the above-mentioned problems, the inventors unexpectedly discovered that the above-mentioned problems could be solved by a three-dimensional knitted fabric comprising a surface layer knitted fabric, a back layer knitted fabric, and a connecting yarn connecting the surface layer knitted fabric and the back layer knitted fabric, wherein at least one of the surface layer n knitted fabric and the back layer knitted fabric comprises a surface layer located on the outside of the three-dimensional knitted fabric, and a shape-fixing layer located on the inside of the three-dimensional knitted fabric and including knit loops formed in the same positions as the knit loops included in the surface layer, and this led to the completion of the present invention.

[0009] That is, the present invention is as follows. [1] A three-dimensional knitted fabric comprising a surface knitted fabric, a back knitted fabric, and a connecting yarn connecting the surface knitted fabric and the back knitted fabric, wherein the surface knitted fabric comprises a surface layer located on the outermost side of the three-dimensional knitted fabric, and a shape-fixing layer located inside the three-dimensional knitted fabric relative to the surface layer and including knit loops formed at the same positions as the knit loops included in the surface layer, and wherein the knit density after finishing is 30 courses / inch or more and 64 courses / inch or less, and the ratio (A) of the number of knit loops included in the surface layer to the number of knit loops included in the shape-fixing layer is more than 80% and 100% or less. [2] The three-dimensional knitted fabric described in [1], wherein the knit loops included in the surface layer and the knit loops included in the shape-fixing layer are all formed in the same position. [3] A three-dimensional knitted fabric according to [1] or [2], wherein in the shape-fixing layer, knit loops that are at least one wale apart are connected by sinker loops. [4] The three-dimensional knitted fabric according to any one of [1] to [3], wherein the shape-fixing layer is a Denbigh knit. [5] A three-dimensional knitted fabric described in any of [1] to [4], wherein the total fineness of the yarns forming each knit loop in all knit loops included in the surface knitted fabric is 100 dtex or more and 1000 dtex or less. [6] A three-dimensional knitted fabric as described in [5], wherein the total fineness of the yarns forming each knit loop in all knit loops included in the surface knitted fabric is 250 dtex or more and 1000 dtex or less. [7] A three-dimensional knitted fabric according to any one of [1] to [6], wherein, among the knit loops included in the surface knitted fabric, for all knit loops including connecting yarns, the value obtained by dividing the fineness of the yarns other than the connecting yarn forming each knit loop by the fineness of the connecting yarn is 2.8 or more. [8] A three-dimensional knitted fabric as described in [7], wherein, among the knit loops contained in the surface knitted fabric, for all knit loops including connecting yarns, the value obtained by dividing the fineness of the yarns other than the connecting yarns forming each knit loop by the fineness of the connecting yarn is 3.0 or more. [9] The following calculation formula for the surface layer knitted fabric: Knit density M=N×√D {where N is the number of stitches (stitches) of the surface layer knitted fabric per 2.54 cm square, and D is the total fineness (dtex) of the fibers forming one stitch of the surface layer knitted fabric.} The three-dimensional knitted fabric according to any one of [1] to [8] above, wherein the stitch density calculated by the formula is 11,500 or more and 20,000 or less.

[10] The three-dimensional knitted fabric according to any one of [1] to [9], wherein the constant load set rate is 3% or less when a tensile load of 10 kg is applied in the warp direction of the three-dimensional knitted fabric for 10 minutes.

[11] The three-dimensional knitted fabric has an air permeability of 33 cc / cm from the connecting layer to the outer knitted fabric. 2 The three-dimensional knitted fabric according to any one of [1] to

[10] above, wherein the knitting speed is 1 / sec or more.

[12] The three-dimensional knitted fabric according to any one of [1] to

[11] , wherein at least one of the knitted fabric of the front layer and the knitted fabric of the back layer contains a heat-sealing yarn.

[13] A vehicle interior material comprising the three-dimensional knitted fabric according to any one of [1] to

[12] above, with the knitted fabric of the surface layer facing the interior of the vehicle.

[14] The vehicle interior material according to

[13] , which is a seat covering material. [Effects of the Invention]

[0010] According to the present invention, there are provided a three-dimensional knitted fabric which suppresses stitch collapse due to excessive elongation when a tensile load is applied, such as when a seat is installed, and which has Taber abrasion resistance and scratch resistance according to the ASTM method, and a vehicle interior material containing the same. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of the present invention will be described in detail. One embodiment of the present invention is a three-dimensional knit fabric comprising a surface layer knitted fabric, a back layer knitted fabric, and a connecting yarn connecting the surface layer knitted fabric and the back layer knitted fabric, wherein the surface layer knitted fabric comprises a surface layer located on the outermost side of the three-dimensional knit fabric, and a shape-fixing layer located inside the three-dimensional knit fabric relative to the surface layer and including knit loops formed at the same positions as the knit loops included in the surface layer, and wherein the knit density after finishing is 30 courses / inch or more and 64 courses / inch or less, and the ratio (A) of the number of knit loops included in the surface layer to the number of knit loops included in the shape-fixing layer is more than 80% and 100% or less.

[0012] The three-dimensional knitted fabric of this embodiment includes a three-dimensional knitted fabric composed of the surface layer knitted fabric, the back layer knitted fabric, and a connecting yarn connecting the surface layer knitted fabric and the back layer knitted fabric. Here, the surface layer refers to the layer that is exposed to the interior surface of a vehicle when used in an interior material for a vehicle. The three-dimensional knitted fabric is knitted by a double Russell warp knitting machine or a double circular knitting machine, and the density of the knitted fabric can be set as desired, but the knitted fabric density after finishing is preferably 30 courses / inch to 64 courses / inch, and more preferably 35 courses / inch to 50 courses / inch. By having the knitted fabric density after finishing be 30 courses / inch to 64 courses / inch, it is possible to achieve a favorable feel as a vehicle interior material and to obtain favorable breathability when seated. To achieve the above knitting density, the gauge of the knitting machine used is 14 to 32, preferably 18 to 28. The on-machine course density during knitting can be set as desired, but in order to adjust the finished knitting density to the above-mentioned preferred range, a double Russell knitting machine is preferably used to knit at a density of 29 courses / inch to 40 courses / inch, more preferably 33 courses / inch to 40 courses / inch. At 29 courses / inch or more, the stitches do not become loose and abrasion resistance is improved. On the other hand, at 40 courses / inch or less, loops tend to come off the knitting needles during knitting, making knitting easier.

[0013] The three-dimensional knitted fabric of this embodiment is characterized in that the surface knitted fabric includes a surface layer located at the outermost side of the three-dimensional knitted fabric, and a shape-fixing layer located inside the three-dimensional knitted fabric relative to the surface layer and including knit loops formed at the same positions as the knit loops included in the surface layer.

[0014] The surface layer is the outermost layer of the three-dimensional knitted fabric, and is the part that greatly affects the design of the three-dimensional knitted fabric. The surface layer can have any design depending on the desired design.

[0015] The shape-fixing layer is located inside the surface layer and contains knit loops formed at the same positions as the knit loops in the surface layer. By providing the shape-fixing layer, the knit loops forming the surface layer are fixed, preventing stitch collapse due to excessive stretching of the knitted fabric and improving Taber abrasion resistance and scratch resistance. It is preferable that the shape-fixing layer itself is exposed to the surface and does not contribute to the design of the three-dimensional knit fabric. The shape-fixing layer can have any design. However, to improve Taber abrasion resistance and scratch resistance by fixing adjacent wales and suppressing knit loop movement, a design in which knit loops separated by one wale or more are connected by sinker loops is preferred. A Denbigh design in which knit loops separated by one wale are connected by sinker loops is more preferred from the perspective of preventing stitch collapse due to warp stretching of the knitted fabric. From the same perspective as above, in the three-dimensional knit fabric of this embodiment, the ratio (A) of the number of knit loops in the surface layer to the number of knit loops in the shape-fixing layer is more than 80% and not more than 100%, preferably more than 90% and not more than 100%. Furthermore, the knit loops included in the surface layer and the knit loops included in the shape-fixing layer may all be formed at the same positions.

[0016] The shape-fixing layer can be formed, for example, by yarn fed from a separate reed located inside the reed used to knit the surface layer in a double Russell knitting machine. Any method can be used to knit the shape-fixing layer. For example, it is preferable to feed yarn from a reed through which the yarn is passed all in, so that the loops of the shape-fixing layer overlap all of the loops of the knitted fabric of the surface layer.

[0017] The fineness of the fibers used in the shape-fixing layer is preferably 50 dtex or more and 150 dtex or less, more preferably 50 dtex or more and 120 dtex or less, and even more preferably 60 dtex or more and 120 dtex or less, from the viewpoints of fixing the surface layer to prevent stitch collapse, improving Taber abrasion resistance and scratch resistance, and preventing the shape-fixing layer from being exposed on the surface.

[0018] The fiber materials used for the front and back knitted fabrics are not limited, and may be a single material or a composite of multiple materials through blending, plying, blending, interweaving, etc. However, from the viewpoints of raw yarn strength and light resistance, polyethylene terephthalate long fibers are preferably used. Furthermore, the fibers used for the front and back knitted fabrics are preferably 100% polyethylene terephthalate fibers in terms of ease of recycling, such as material recycling and chemical recycling. Furthermore, from the viewpoint of increasing the pull-out resistance of single fibers and improving scratch resistance, the polyethylene terephthalate fiber is preferably false-twisted yarn, interlaced yarn, or twisted yarn. The fibers used for the front and back knitted fabrics are preferably spun yarn (yarn colored by kneading pigments, etc.) or yarn-dyed yarn in order to suppress changes in the properties of the three-dimensional knitted fabric due to dyeing, and more preferably spun yarn, which eliminates the need for a dyeing process.

[0019] The fineness of the fibers used in the front and back knitted fabrics is preferably 50 dtex to 500 dtex, more preferably 50 dtex to 250 dtex, and even more preferably 60 dtex to 250 dtex, from the viewpoint of suppressing stitch collapse due to warp elongation. From the same viewpoint, in all knit loops included in the knitted fabric on the side having the shape-fixing layer, of the front and back knitted fabrics, the total fineness of the yarns forming each knit loop is preferably 100 dtex to 1200 dtex, more preferably 100 dtex to 1000 dtex, even more preferably 250 dtex to 1000 dtex, and particularly preferably 250 dtex to 700 dtex. When the fibers used for the front and back knitted fabrics are multifilaments, the single yarn fineness is preferably 1 dtex or more and 6 dtex or less, more preferably 3 dtex or more and 6 dtex or less, which increases the strength of the single yarn.

[0020] The fiber material used for the connecting yarn may be the same as the fiber used for the knitted fabric of the front layer and the knitted fabric of the back layer described above.

[0021] The fiber used for the connecting yarn may be either a multifilament or a monofilament, but is preferably a monofilament. When a monofilament is used for the connecting yarn, the fineness thereof is preferably 30 dtex or more and 300 dtex or less, more preferably 50 dtex or more and 200 dtex or less, in order to prevent the monofilament from protruding from the knitted fabric surface and to maintain good cushioning properties.

[0022] If the connecting yarns protrude from the surface of the three-dimensional knitted fabric, they will easily get caught on protrusions such as hooks on hook-and-loop fasteners, reducing scratch resistance. Therefore, it is desirable that the stitches of the fibers forming the surface knitted fabric press down the stitches of the connecting yarns so that the connecting yarns do not protrude from the outer surface of the surface knitted fabric (i.e., the seating surface of the seat cover material).To achieve this, it is preferable that, among the knit loops included in the knitted fabric on the side having the shape-fixing layer, for all knit loops including the connecting yarns, the value obtained by dividing the fineness D1 of the yarns other than the connecting yarns forming each knit loop by the fineness D2 of the connecting yarn (hereinafter also referred to as ``D1 / D2'') is 2.8 or more, and more preferably 3.0 or more.

[0023] In the three-dimensional knitted fabric of this embodiment, it is preferable that the knitting structure of the surface layer knitted fabric and the back layer knitted fabric, which do not include the surface layer and shape-fixing layer, use at least two reeds and, when supplying yarn from the guide bar, have a mesh structure with a yarn withdrawal arrangement such as 1-in-1-out or 2-in-2-out.

[0024] In the three-dimensional knitted fabric of this embodiment, the knitted fabric of the surface layer is calculated by the following formula: Knit density M=N×√D {where N is the number of stitches (pieces) of the surface layer knitted fabric per 2.54 cm square, and D is the total fineness (dtex) of the fibers forming one stitch of the surface layer knitted fabric.} is preferably 11,500 or more and 20,000 or less. Here, "the total fineness (dtex) of the fibers forming one stitch of the surface knitted fabric" refers to the total fineness of only the fibers forming the stitch, excluding the fineness of the connecting yarn and fibers that do not form a stitch, such as insert knitting.

[0025] When the stitch density of the surface knitted fabric is 11,500 or more, protrusions such as hooks of a hook-and-loop fastener are less likely to get caught on the monofilaments of the surface knitted fabric, which tends to favorably prevent the monofilaments from being cut and becoming frayed. When the stitch density of the surface knitted fabric is 20,000 or less, the breathability of the surface knitted fabric can be increased, facilitating the transfer of heat and moisture due to air convection, which tends to improve the cool feeling when sitting or touching the fabric when used in vehicle interior materials and reduce the feeling of stuffiness. From the viewpoint of further suppressing fuzzing due to protrusions and improving the cool feeling and stuffiness, the stitch density of the surface knitted fabric is preferably in the range of 13,000 to 19,000, more preferably 14,000 to 19,000.

[0026] The three-dimensional knit fabric of this embodiment preferably has a constant load set rate of 3% or less when a load of 10 kg is applied in the warp direction of the fabric for 10 minutes, then the load is removed and the fabric is allowed to stand for 10 minutes, from the viewpoint of preventing excessive elongation during sheet tensioning and preventing stitch collapse. A detailed method for measuring the constant load set rate will be described later.

[0027] The three-dimensional knitted fabric of this embodiment transfers heat and moisture from the human body when seated, providing good coolness and preventing stuffiness, and has an air permeability of 33 cc / cm from the layer between the surface knitted fabric and the back knitted fabric of the three-dimensional knitted fabric (hereinafter also referred to as the "connecting layer") to the surface knitted fabric. 2 / sec or more, and more preferably 40 cc / cm 2 / sec or more, and more preferably 50 cc / cm 2 / sec or more.

[0028] In this specification, the term "air permeability that penetrates from the layer between the surface knitted fabric and the back knitted fabric of a three-dimensional knitted fabric toward the surface knitted fabric" refers to the air permeability of a three-dimensional knitted fabric when the air permeability is measured in accordance with the suction conditions of JIS L1096 Air Permeability Testing Method (Method A), where a test piece of the three-dimensional knitted fabric is 15 cm square, the surface knitted fabric is placed face down in the opening of an air permeability testing machine, and a 3 mm thick, 20 cm square silicone rubber plate is placed on the outer surface of the back knitted fabric to block the air from permeating the back knitted fabric, and the air permeability that enters the cross section of the four sides of the three-dimensional knitted fabric, passes through the connecting layer, and permeates the surface knitted fabric.

[0029] The air permeability of a three-dimensional knitted fabric, measured by the general JIS L1096 air permeability test method (method A), is 60cc / cm. 2 / sec or more, and more preferably 70 cc / cm 2 / sec or more, more preferably 90cc / cm 2 / sec or more. The air permeability from the back knitted fabric to the surface knitted fabric is 60cc / cm 2 By setting the air flow rate to 1 / sec or more, the material is more suitable as a seat covering material to be used in combination with a cushion member incorporating a ventilation system.

[0030] In the three-dimensional knit fabric of this embodiment, from the viewpoint of fixing the stitches of the surface layer to prevent the stitches from collapsing and improving Taber abrasion resistance and scratch resistance, it is preferable that at least one of the surface layer knitted fabric and the back layer knitted fabric, particularly the shape-fixing layer, contains a heat-sealed yarn. Here, "heat-sealed yarn" refers to a yarn having a lower melting point than the other fibers contained in the surface layer knitted fabric and the back layer knitted fabric. The heat-sealed yarn preferably has a melting point of 200°C or less, more preferably 180°C or less. The material of the low-melting-point yarn is not limited, and multiple materials may be combined by blending, plying, blending, etc., but long fibers of polyethylene terephthalate-based fibers are preferably used in terms of strength and light resistance.

[0031] The thickness of the three-dimensional knitted fabric of this embodiment can be set arbitrarily, but is preferably 2 mm or more and 12 mm or less, more preferably 2.5 mm or more and 8 mm or less, in view of ease of sewing and handling as a skin material. The basis weight of the three-dimensional knitted fabric can be set arbitrarily, but is preferably 150 to 1000 g / m 2 , more preferably 400 to 900 g / m 2 is.

[0032] In the finishing method for the three-dimensional knit fabric constituting the three-dimensional knit fabric of this embodiment, in the case of a three-dimensional knit fabric using yarn-dyed yarn or spun-dyed yarn, the grey fabric can be finished through processes such as scouring and heat setting, but in terms of process simplification, finishing by heat setting alone is more preferable. In the case of a three-dimensional knit fabric in which the connecting yarn or the fibers used in the surface layer knitted fabric and the back layer knitted fabric are uncolored, the grey fabric can be finished through processes such as presetting, scouring, dyeing, and heat setting.

[0033] The three-dimensional knitted fabric of this embodiment is suitably used as an interior material for a vehicle, with the knitted fabric including the shape-fixing layer of the front and back layer knitted fabrics facing the interior side. [Example]

[0034] EXAMPLES The present invention will be specifically explained below with reference to Examples and Comparative Examples, but the present invention is not limited to the Examples alone. The methods for measuring various physical properties of the three-dimensional knitted fabrics used in the following examples are as follows.

[0035] (a) The ratio (%) of the number of knit loops in the surface layer to the number of knit loops in the shape-fixing layer (A) With the weft direction of the three-dimensional knit fabric as the width direction and the warp direction as the length direction, a test piece 100 mm wide x 100 mm long is taken, and the loops in the shape-fixing layer and surface layer are counted and calculated using the formula below. Measurements are taken in three places and the average value is calculated.

number

[0036] (b) Constant load set rate (%) when a 10 kg tensile load is applied in the warp direction for 10 minutes A test piece measuring 80 mm wide x 250 mm long was taken, with the weft direction of the three-dimensional knitted fabric as the width direction and the warp direction as the length direction, and a 100 mm benchmark was drawn in the center of the width and length directions of the test piece. The test piece was attached to a constant load elongation tester FLM-3M manufactured by Daiei Scientific Instruments Co., Ltd., and weights were attached so that the total tensile load applied to the test piece in the length direction was 10 kg. After applying a tensile load of 10 kg for 10 minutes, the test piece was removed and left to stand on a horizontal table for 10 minutes, and the length of the benchmark was measured in this state, and the following formula was used:

number

[0037] (c) Stitch collapse rate (%) when a tensile load of 10 kg is applied in the warp direction A test piece measuring 80 mm wide x 250 mm long was taken from the three-dimensional knitted fabric, with the weft direction as the width direction and the warp direction as the length direction. Two marks were made from the center of the test piece, 2.5 cm apart in the length direction and two marks 2.5 cm apart in the width direction. The test piece was attached to a constant-load elongation tester FLM-3M manufactured by Daiei Kagaku Seiki Seisakusho, and weights were attached so that the total load applied to the test piece in the length direction was 10 kg. After applying a tensile load of 10 kg for 10 minutes, the length between the marks in the length direction and the width direction were measured in this state, and the following formula was used:

number

[0038] (d) Air permeability from the connecting layer to the outer knitted fabric (cc / cm 2 / sec) Using a Takayama Reed FX3300 Laboair IV breathability tester, a 15cm square test piece was placed with the surface knit fabric of the three-dimensional knit fabric facing downwards in the opening of the breathability tester, and a 3mm thick, 20cm square silicone rubber plate was placed on the outer surface of the back knit fabric.The test head of the breathability tester was pressed against it and fixed in place with a clamp, and the breathability that entered through the connecting layer of the cross section of the four sides of the three-dimensional knit fabric and passed through the surface knit fabric was measured under suction conditions in accordance with JIS L1096 Breathability Test Method (Method A).

[0039] (e) Air permeability (cc / cm 2 / sec) Using a Takayama Reed FX3300 Laboair IV breathability tester, the air permeability from the back knitted fabric to the front knitted fabric of a three-dimensional knitted fabric is measured in accordance with JIS L1096 breathability test method (method A).

[0040] (f) Scratch resistance (grade) Using a Daiei Scientific Instruments Co., Ltd. flat abrasion tester, a three-dimensional knitted fabric measuring 8 cm wide and 31 cm long was placed on the flat abrasion table of the flat abrasion tester with the outer knitted fabric facing up and both ends secured with clamps. Next, a 5 cm long Velcro® tape (Kuraray Fastening Co., Ltd.) A8693Y.71 was attached to the friction element with the hook side facing outward. The friction element was placed on the test piece and subjected to a five-reciprocal abrasion test with a pressure load of 9.8 N (including the friction element), a stroke of 14 cm, and a speed of 60±10 reciprocations / min. Test pieces were taken from the warp and weft directions of the three-dimensional knitted fabric and measured. After the test, the surface wear condition of the test piece was observed and graded as follows. The grade was determined in 0.5-grade increments. Grade 5: No pilling observed Grade 4: Slight pilling is observed Grade 3: Pilling is clearly visible, but broken threads are not noticeable. Grade 2: Slightly noticeable pilling, broken threads, and pulled threads Grade 1: Significant fuzzing and severe appearance abnormalities

[0041] (g) Taber wear resistance (JASO method) (grade) According to JASOM403 Method A (Taber rotary abrader method), a Taber type abrasion tester is used, and the test piece is subjected to 1000 abrasion cycles at a load of 500g and a speed of 70 rpm using a CS-10 abrasion wheel. After the test, the abrasion condition of the surface of the test piece is observed and judged as follows. The judgement is made in 0.5 grade increments. Grade 5: No change in surface condition Grade 4: Slightly fuzzy Grade 3: Lots of fluff Grade 2: There is a lot of fluffing and the thread is thin. Grade 1: Thread breakage.

[0042] (h) Taber abrasion resistance (ASTM method) (grade) According to ASTM 3884-9 method (rotating platform double head method), a Taber abrasion tester is used, and the test piece is abraded 1000 times with a CS-10 abrasion wheel at a load of 1000g and a speed of 72 rpm. After the test, the abrasion condition of the surface of the test piece is observed, and the following grade is determined according to JASOM403 A method. The grade is determined in 0.5 grade increments. Grade 5: No change in surface condition Grade 4: Slightly fuzzy Grade 3: Lots of fluff Grade 2: There is a lot of fluffing and the thread is thin. Grade 1: Thread breakage.

[0043] (i) Tactile evaluation (grade) A 15cm square sample is taken and conditioned in a constant temperature and humidity chamber at a temperature of 20°C and a humidity of 65% for at least 8 hours. Ten subjects were selected, and while blindfolded, they touched the fabric in the temperature and humidity controlled room by rubbing it up and down with four fingers (excluding the thumb), and judged it according to the following criteria, in increments of 0.5. The average score of the 10 subjects was recorded. Level 5: Feeling strong and comfortable Level 4: Feeling a little comfortable Grade 3: Neither comfortable nor uncomfortable Grade 2: Feeling a little uncomfortable Grade 1: Severe discomfort

[0044] [Example 1] Using a 22 gauge, 6mm double raschel knitting machine equipped with six reeds, two strands of 167dtex 48 filament polyethylene terephthalate fiber (black dyed yarn) false twist textured yarn were fed from two reeds (L1, L2) in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement, and one reed (L3) formed a shape-fixed layer with 84dtex 24 filament polyethylene terephthalate fiber (black dyed yarn) false twist textured yarn. The false twisted yarn was supplied in an all-in arrangement, and monofilament 110 dtex polyethylene terephthalate fiber (black dyed yarn) was supplied in a 1-in-1-out (L4) arrangement from one reed (L4) that formed the connecting part, and further, false twisted yarn of 110 dtex 36 filament polyethylene terephthalate fiber (black dyed yarn) was supplied in an all-in arrangement from two reeds (L5, L6) that formed the knitted fabric of the back layer. A three-dimensional knit fabric was knitted using the knitting structure shown below with 35 courses per 2.54 cm on the machine. The resulting gray fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 37 courses per inch and 24 wales per inch. (edited organization) L1:0111 / 2122 / 5444 / 3433 / / (1 in 1 out) L2: 4544 / 4333 / 1011 / 1222 / / (1 out, 1 in) L3: 0111 / 2111 / 1011 / 1211 / / (All in) L4: 3410 / 3245 / 2145 / 2310 / / (1 out 1 in) L5:1110 / 1112 / / (All-in) L6:1123 / 2210 / / (All in)

[0045] [Example 2] A three-dimensional knitted fabric with a finished knit density of 37 courses / inch and 24 wales / inch was obtained in the same manner as in Example 1, except that the weaves of L1, L2, L3, and L4 were changed as follows. (edited organization) L1:0111 / 3222 / 0111 / 3222 / / (1 in 1 out) L2: 2322 / 1011 / 2322 / 1011 / / (1 out, 1 in) L3: 1211 / 1011 / 1211 / 1011 / / (All-in) L4: 3410 / 4367 / 3410 / 4367 / / (1 in 1 out)

[0046] [Example 3] A three-dimensional knitted fabric having a finished knit density of 37 courses / inch and 24 wales / inch was obtained in the same manner as in Example 1, except that the structure of L3 was changed as follows. (edited organization) L3: 0111 / 3222 / 1011 / 2322 / / (All-in)

[0047] [Example 4] A three-dimensional knitted fabric having a finished knit density of 37 courses / inch and 24 wales / inch was obtained in the same manner as in Example 1, except that the structure of L3 was changed as follows. (edited organization) L3: 0111 / 4333 / 1011 / 3433 / / (All-in)

[0048] [Example 5] Using a double Russell knitting machine with 6 reeds, 18 gauge, and 6 mm between the hooks, two reeds (L1, L2) that form the surface knitting fabric are fed with two parallel twisted yarns of 222 dtex 72 filament polyethylene terephthalate fiber (black dope-dyed yarn) in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement, and one reed (L3) that forms the shape-fixed layer is fed with 110 dtex 36 filament polyethylene terephthalate fiber ( A false twisted yarn of 110 dtex polyethylene terephthalate fiber (black dope-dyed yarn) was supplied in an all-in arrangement, and a monofilament of 110 dtex polyethylene terephthalate fiber (black dope-dyed yarn) was supplied in a 1-in-1-out (L4) arrangement from one reed (L4) that formed the connecting part, and further, false twisted yarn of 110 dtex 36 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied in an all-in arrangement from two reeds (L5, L6) that formed the knitted fabric of the back layer. A three-dimensional knit fabric was knitted using the knitting structure shown below with 29 courses per 2.54 cm on the machine. The resulting grey fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 31 courses per inch and 20 wales per inch. (edited organization) L1:0111 / 2122 / 5444 / 3433 / / (1 in 1 out) L2: 4544 / 4333 / 1011 / 1222 / / (1 out, 1 in) L3: 0111 / 2111 / 1011 / 1211 / / (All in) L4: 3410 / 3245 / 2145 / 2310 / / (1 out 1 in) L5:1110 / 1112 / / (All-in) L6:1123 / 2210 / / (All in)

[0049] [Example 6] Using a double Russell knitting machine with 28 gauge and 3mm hook interval equipped with six reeds, two strands of 56dtex 18 filament polyethylene terephthalate fiber (black spun-dyed yarn) false twist textured yarn were fed from the two reeds (L1, L2) that form the surface knitted fabric in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement, and one reed (L3) that forms the shape-fixed layer fed two strands of 56dtex 18 filament polyethylene terephthalate fiber (black spun-dyed yarn) false twist textured yarn. A false twisted yarn of 56 dtex 18 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied in an all-in arrangement, and a monofilament of 60 dtex polyethylene terephthalate fiber (black dope-dyed yarn) was supplied in a 1-in-1-out (L4) arrangement from one reed (L4) that formed the connecting part, and further, two false twisted yarns of 56 dtex 18 filament polyethylene terephthalate fiber (black dope-dyed yarn) were pulled together and supplied all in an all-in arrangement from two reeds (L5, L6) that formed the knitted fabric of the back layer. A three-dimensional knit fabric was knitted using the knitting structure shown below with 40 courses per 2.54 cm on the machine. The resulting grey fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 42 courses per inch and 30 wales per inch. (edited organization) L1:0111 / 2122 / 5444 / 3433 / / (1 in 1 out) L2: 4544 / 4333 / 1011 / 1222 / / (1 out, 1 in) L3: 0111 / 2111 / 1011 / 1211 / / (All in) L4: 3410 / 3245 / 2145 / 2310 / / (1 out 1 in) L5:1110 / 1112 / / (All-in) L6:1123 / 2210 / / (All in)

[0050] [Example 7] A three-dimensional knitted fabric with a finished knit density of 37 courses / inch and 24 wales / inch was obtained in the same manner as in Example 1, except that the L3 yarn was changed to an 84 dtex, 24 filament low-melting polyester yarn (Bell Couple (registered trademark) manufactured by KB Seiren Co., Ltd.) and the heat setting conditions were changed to 190°C x 1 minute.

[0051] [Example 8] A three-dimensional knitted fabric having a finished knitting density of 37 courses / inch and 24 wales / inch was obtained in the same manner as in Example 1, except that the yarn removal sequence of L1L2 was changed as follows. (edited organization) L1: 0111 / 2122 / 5444 / 3433 / / (1 in 1 out x 4 repeats + 2 out) L2: 4544 / 4333 / 1011 / 1222 / / (1 out 1 in x 4 repeats + 2 out)

[0052] [Comparative Example 1] A 22-gauge, 6mm-drum double Russell knitting machine equipped with six reeds was used. Two strands of 167dtex, 48-filament polyethylene terephthalate fiber (black dyed yarn) false-twisted yarn were fed from the two reeds (L1, L2) that formed the surface knitted fabric in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement. One reed (L4) that formed the connecting part fed a monofilament of 110dtex polyethylene terephthalate fiber (black dyed yarn) in a 1-in-1-out (L4) arrangement. Furthermore, two reeds (L5, L6) that formed the back knitted fabric fed a 110dtex, 36-filament polyethylene terephthalate fiber (black dyed yarn) false-twisted yarn, both in an all-in arrangement. A three-dimensional knit fabric was knitted using the knitting structure shown below with 35 courses per 2.54 cm on the machine. The resulting gray fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 37 courses per inch and 24 wales per inch. (edited organization) L1: 1011 / 1222 / 4544 / 4333 / / (1 in 1 out) L2: 4544 / 4333 / 1011 / 1222 / / (1 out, 1 in) L3: No thread supply L4: 3410 / 3245 / 2145 / 2310 / / (1 in 1 out) L5:1110 / 1112 / / (All-in) L6:1123 / 2210 / / (All in)

[0053] Comparative Example 2 A 22-gauge, 1.8mm double-russel knitting machine equipped with six reeds was used. Two reeds (L1, L2) supplied 84 dtex, 36 filament polyethylene terephthalate (black dope-dyed) false-twisted yarn in a 3-in, 1-out (L1, L2) arrangement. One reed (L3), which forms the shape-fixing layer, supplied 84 dtex, 36 filament polyethylene terephthalate (black dope-dyed) false-twisted yarn in an all-in arrangement. One reed (L4), which forms the connecting section, supplied 33 dtex, 12 filament polyethylene terephthalate (black dope-dyed) false-twisted yarn in an all-in (L4) arrangement. Furthermore, two reeds (L5, L6), which form the back layer knitted fabric, supplied 84 dtex, 36 filament polyethylene terephthalate (black dope-dyed) false-twisted yarn in an all-in arrangement. A three-dimensional knit fabric was knitted using the knitting structure shown below with 32 courses per 2.54 cm on the machine. The resulting grey fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 34 courses per inch and 24 wales per inch. (edited organization) L1: 0000 / 0000 / 0100 / 0100 / / (3 in 1 out) L2: 0100 / 0100 / 0000 / 0000 / / (3 in 1 out) L3:3433 / 1011 / / (All in) L4:0112 / 2110 / / (All in) L5:0111 / 1000 / / (All in) L6:1011 / 3433 / / (All-in)

[0054] Comparative Example 3 Using a 9-gauge, 12mm double raschel knitting machine equipped with six reeds, crimped yarn of 833 dtex 192 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied from two reeds (L1, L2) in an arrangement of 1 in 1 out (L1) and 1 out 1 in (L2), and false twisted yarn of 250 dtex 72 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied from one reed (L3) which forms the shape-fixed layer. The yarns were supplied in an all-in arrangement, and from one reed (L4) that formed the connecting part, a monofilament of 667 dtex polyethylene terephthalate fiber (black dyed yarn) was supplied in an all-in (L4) arrangement.Furthermore, from two reeds (L5, L6) that formed the knitted fabric of the back layer, crimped yarn of 833 dtex 192 filament polyethylene terephthalate fiber (black dyed yarn) was supplied in an 1-in-1-out (L5) and 1-out-1-in (L6) arrangement. A three-dimensional knit fabric was knitted using the knitting structure shown below with 11 courses per 2.54 cm on the machine. The resulting grey fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 13 courses per inch and 11 wales per inch. (edited organization) L1: 1011 / 1211 / 1011 / 2322 / 2122 / 2322 / / (1 in 1 out) L2: 2322 / 2122 / 2322 / 1011 / 1211 / 1011 / / (1 out, 1 in) L3:1011 / / (All in) L4:2110 / 1223 / / (All in) L5: 1011 / 1211 / 1011 / 2322 / 2122 / 2322 / / (1 in 1 out) L6: 2322 / 2122 / 2322 / 1011 / 1211 / 1011 / / (1 out, 1 in)

[0055] Comparative Example 4 Using a double Russell knitting machine with 18 gauge and 15 mm hook interval equipped with six reeds, false twisted yarn of 222 dtex 60 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied from two reeds (L1, L2) in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement, and false twisted yarn of 110 dtex 36 filament polyethylene terephthalate fiber (black dope-dyed yarn) was supplied from one reed (L3) which forms the shape-fixed layer. The yarns were supplied in an all-in arrangement, and monofilaments of 333 dtex polyethylene terephthalate fiber (black dyed yarn) were supplied in an all-in (L4) arrangement from one reed (L4) that formed the connecting part.Furthermore, crimped yarns of 222 dtex 60 filament polyethylene terephthalate fiber (black dyed yarn) were supplied in a 1-in-1-out (L5) and 1-out-1-in (L6) arrangement from two reeds (L5, L6) that formed the knitted fabric of the back layer. A three-dimensional knit fabric was knitted using the knitting structure shown below with 24 courses per 2.54 cm on the machine. The resulting grey fabric was widened by 5% and dry heat set at 180°C for 1 minute with an overfeed rate of 0%, resulting in a three-dimensional knit fabric with a finished knit density of 26 courses per inch and 20 wales per inch. L1: 1011 / 1211 / 1011 / 2322 / 2122 / 2322 / / (1 in 1 out) L2: 2322 / 2122 / 2322 / 1011 / 1211 / 1011 / / (1 out, 1 in) L3:1211 / 1011 / / (All in) L4:4554 / 3210 / 0123 / / (All in) L5:1000 / 0111 / / (1 in 1 out) L6:3433 / 1011 / / (1 out 1 in)

[0056] The results of the above examples and comparative examples are summarized in Tables 1 and 2 below.

[0057] [Table 1]

[0058] [Table 2]

[0059] As shown in Tables 1 and 2, the three-dimensional knitted fabrics of Examples 1 to 8 had a good feel, good Taber abrasion resistance and scratch resistance according to the ASTM standard, and little collapse of the stitches when subjected to a tensile load. In contrast, in Comparative Examples 1 and 2, there was no shape-fixing layer, or the ratio (A) of the number of knit loops in the surface layer to the number of knit loops in the shape-fixing layer was 75%, so the Taber abrasion resistance according to the ASTM standard was poor and the knitted loops collapsed significantly under tensile load. Furthermore, in Comparative Example 3, the knitted fabric density after finishing was low and excessively thick yarn was used to maintain strength, so although the Taber abrasion resistance and scratch resistance according to the ASTM standard were good, the feel was unpleasant and the knitted loops collapsed significantly under tensile load. Furthermore, in Comparative Example 4, the knitted fabric density after finishing was low and the feel was good, but the Taber abrasion resistance and scratch resistance according to the ASTM standard were poor and the knitted loops collapsed significantly under tensile load. Industrial Applicability

[0060] The three-dimensional knitted fabric of the present invention suppresses stitch collapse due to excessive elongation when a tensile load is applied, such as when a seat is installed, and has Taber abrasion resistance and scratch resistance according to the ASTM method, making it suitable for use as an interior material for vehicles.

Claims

1. A three-dimensional knitted fabric comprising a surface layer knitted fabric, a back layer knitted fabric, and a connecting yarn connecting the surface layer knitted fabric and the back layer knitted fabric, wherein the surface layer knitted fabric comprises a surface layer located on the outermost side of the three-dimensional knitted fabric, and a shape-fixing layer located inside the three-dimensional knitted fabric relative to the surface layer and including knit loops formed at the same positions as the knit loops included in the surface layer, the three-dimensional knitted fabric having a knit density after finishing of 30 courses / inch or more and 64 courses / inch or less, the ratio (A) of the number of knit loops included in the surface layer to the number of knit loops included in the shape-fixing layer being more than 80% and 100% or less, and the knit loops of the shape-fixing layer overlap all of the knit loops of the surface layer.

2. The three-dimensional knitted fabric according to claim 1 , wherein the knit loops included in the surface layer and the knit loops included in the shape-fixing layer are all formed at the same positions.

3. The three-dimensional knitted fabric according to claim 1 or 2, wherein in the shape-fixing layer, knit loops spaced apart by one wale or more are connected to each other by sinker loops.

4. The three-dimensional knitted fabric according to claim 1 or 2, wherein the shape-fixing layer is a Denbigh knit.

5. 3. The three-dimensional knitted fabric according to claim 1 or 2, wherein the total fineness of the yarns forming all the knit loops included in the knitted fabric of the surface layer is 100 dtex or more and 1000 dtex or less.

6. 6. The three-dimensional knitted fabric according to claim 5, wherein the total fineness of the yarns forming all the knit loops included in the knitted fabric of the surface layer is 250 dtex or more and 1000 dtex or less.

7. A three-dimensional knitted fabric as described in claim 1 or 2, wherein, among the knit loops included in the surface knitted fabric, for all knit loops including connecting yarns, the value obtained by dividing the fineness of the yarns other than the connecting yarns forming each knit loop by the fineness of the connecting yarn is 2.8 or more.

8. A three-dimensional knitted fabric as described in claim 7, wherein, among the knit loops included in the surface knitted fabric, for all knit loops including connecting yarns, the value obtained by dividing the fineness of the yarns other than the connecting yarns forming each knit loop by the fineness of the connecting yarn is 3.0 or more.

9. The following calculation formula for the surface layer knitted fabric: Knit density M=N×√D {where N is the number of stitches (stitches) of the surface layer knitted fabric per 2.54 cm square, and D is the total fineness (dtex) of the fibers forming one stitch of the surface layer knitted fabric.} The three-dimensional knitted fabric according to claim 1 or 2, wherein the stitch density calculated by the formula is 11,500 or more and 20,000 or less.

10. 3. The three-dimensional knitted fabric according to claim 1, wherein the constant load set rate when a tensile load of 10 kg is applied in the warp direction of the three-dimensional knitted fabric for 10 minutes is 3% or less.

11. The air permeability of the three-dimensional knitted fabric from the connecting layer to the front knitted fabric is 33 cc / cm ２ The three-dimensional knitted fabric according to claim 1 or 2, wherein the knitting time is 1 / sec or more.

12. The three-dimensional knitted fabric according to claim 1 or 2, wherein at least one of the knitted fabric of the front layer and the knitted fabric of the back layer contains a heat-sealable yarn.

13. 3. A vehicle interior material comprising the three-dimensional knitted fabric according to claim 1 or 2, wherein the knitted fabric of the surface layer and the knitted fabric of the back layer are positioned on the interior side of the vehicle.

14. The vehicle interior material according to claim 13, which is a seat covering material.

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