Seat upholstery material and seats containing such seat upholstery material

Abstract

This invention provides a seat upholstery material for use in vehicles, furniture, and the like. This material exhibits excellent appearance due to its concave deformable portion, and suppresses pilling even when rubbed against the surface by hard protrusions such as hooks on hook-and-loop fasteners. Furthermore, it provides excellent cushioning by suppressing lateral tipping. The seat upholstery material of this invention is composed of a three-dimensional woven fabric comprising two knitted layers—an outer layer and an inner layer—and connecting yarns linking these two knitted layers together. The three-dimensional woven fabric is characterized by having a concave deformable portion on the outer layer side, and a parameter A calculated using the following formula being 6 or more and 36 or less: Parameter A = Loop row density (loop row / 2.54cm) × Concave portion thickness (mm) / Fabric thickness (mm).

Description

Technical Field

[0001] This invention relates to seat upholstery materials and seats containing the same upholstery material. Background Technology

[0002] In the past, for three-dimensional knitted fabrics consisting of two layers of knitted fabric and connecting yarns that connect the two layers of knitted fabric, the connecting yarns use monofilaments and have cushioning properties in the thickness direction, and the knitted fabrics of the two layers form a mesh structure to ensure high breathability. As a cool and stuffy cushioning material, it has been widely used in seats, bedding and other applications.

[0003] On the other hand, when three-dimensional woven fabrics are used as surface materials for seats, the surface of the cushioning material is embossed to create a textured surface, resulting in a high aesthetic appeal. However, the surface abrasion resistance and other durability and cushioning properties required for the seat are poor.

[0004] Patent document 1 discloses that by having a gradient portion in which the height from the bottom of the recess gradually changes from the recess to the non-recessed portion of the cushioning material, a sheet material with excellent appearance is obtained by having a layer from the recess to the non-recessed portion.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2019-104217 Summary of the Invention

[0008] The problem the invention aims to solve

[0009] However, in Patent Document 1, no consideration is given to suppressing the surface condition caused by wear and the suppression of lateral tilting caused by the formation of recesses. The performance in suppressing the wear caused by friction from protrusions and the cushioning obtained by suppressing lateral tilting are insufficient.

[0010] In view of the above-mentioned level of the prior art, the problem to be solved by the present invention is to solve the above-mentioned problems of the prior art by providing a seat cover material and a seat containing the seat cover material. The seat cover material is a cover material for seats of vehicles, furniture, etc. It has excellent appearance due to having concave deformable parts, and can suppress the generation of fuzz even when the surface is rubbed by hard protrusions such as hooks of hook and loop fasteners. In addition, it has excellent cushioning by suppressing lateral tipping.

[0011] Solution for solving the problem

[0012] In order to solve the above-mentioned problems, the inventors of the present invention conducted in-depth research and repeated experiments. As a result, they unexpectedly discovered a seat cover material formed by a three-dimensional woven fabric. The three-dimensional woven fabric consists of two layers of knitted fabric and connecting yarns connecting the two layers of knitted fabric. By forming a concave deformation part on the surface side of the three-dimensional woven fabric and making the parameter A calculated based on the loop density of the three-dimensional woven fabric, the thickness of the deformation part (concave part), and the fabric thickness within a specific range, the above-mentioned problems can be solved, thus completing the present invention.

[0013] That is, the present invention is as follows.

[0014] [1] A seat cover material comprising a three-dimensional woven fabric, the three-dimensional woven fabric comprising: two knitted fabrics, having an outer layer and an inner layer; and connecting yarns that connect the two knitted fabrics to each other, characterized in that the three-dimensional woven fabric has a concave deformable portion in at least one layer, and the parameter A calculated by the following formula is 6 or more and 36 or less:

[0015] Parameter A = Coil row density (coil row / 2.54cm) × concave thickness (mm) / fabric thickness (mm).

[0016] [2] According to the seat cover material described in [1], the concave deformable portion is formed over five or more consecutive coil rows.

[0017] [3] According to the seat cover material described in [1] or [2], the concave deformation portion is continuously formed on the same coil longitudinal row, covering 60 coil rows or less.

[0018] [4] The seat cover material according to any one of [1] to [3], wherein the three-dimensional woven fabric has a plurality of concave deformable portions, and the closest concave deformable portions on the same coil longitudinal row are spaced apart from each other by more than 10 mm and less than 300 mm.

[0019] [5] According to the seat cover material described in [4], the closest concave deformation portions on the same longitudinal coil are spaced apart by more than 15 mm and less than 300 mm.

[0020] [6] The seat cover material according to any one of [1] to [4], wherein the concave deformed portion is formed by fusing fibers together.

[0021] [7] According to the seat cover material described in [5], the concave deformed portion is formed by fusing fibers together.

[0022] [8] The seat cover material according to any one of [1] to [5], wherein the concave deformed portion is formed by embroidery or sewing.

[0023] [9] The seat cover material according to any one of [1] to [8], wherein the coil density of the surface layer of the three-dimensional woven fabric is 11,500 or more and 23,000 or less.

[0024]

[10] According to the seat cover material described in [9], the coil density of the surface layer of the three-dimensional woven fabric is 13,000 or more and 23,000 or less.

[0025]

[11] A seat, wherein the seat comprises the seat cover material described in any one of [1] to

[10] .

[0026] The effects of the invention

[0027] The seat cover material of the present invention has excellent appearance due to having concave deformable portions, and can suppress the generation of pilling even when rubbed by hard protrusions such as the hooks of the hook and loop fasteners. In addition, it can have excellent cushioning by suppressing lateral tilting. Attached Figure Description

[0028] Figure 1 The diagram shows the concave deformation portions of Examples 1, 2, 3, 6, 9, 10, 11, 15 and Comparative Examples 1 and 2.

[0029] Figure 2 This is a diagram showing the concave deformation portion of embodiments 4, 7, and 12.

[0030] Figure 3 This is a diagram showing the concave deformation portion of embodiments 5 and 13.

[0031] Figure 4 This is a diagram showing the concave deformed portion of embodiments 8 and 14. Detailed Implementation

[0032] The embodiments of the present invention will be described in detail below.

[0033] One embodiment of the present invention provides a seat cover material comprising a three-dimensional woven fabric, the three-dimensional woven fabric comprising: two knitted layers, having an outer layer and an inner layer; and connecting yarns that connect the two knitted layers to each other, characterized in that the three-dimensional woven fabric has a concave deformable portion in at least one layer, and the parameter A calculated by the following formula is 6 or more and 36 or less:

[0034] Parameter A = Coil row density (coil row / 2.54cm) × concave thickness (mm) / fabric thickness (mm).

[0035] The seat upholstery material of this embodiment comprises a three-dimensional woven fabric, which consists of two layers of knitted fabric and a connecting thread that links the two layers of knitted fabric. The three-dimensional woven fabric is knitted using a double Raschel warp knitting machine or a double circular knitting machine, preferably using a machine size of 18 to 28.

[0036] The three-dimensional woven fabric constituting the seat cover material of this embodiment needs to have concave deformable portions in at least one layer. By having one or more of these concave deformable portions, the cover material of this embodiment exhibits a superior three-dimensional appearance. A concave deformable portion refers to a thinner region on the surface of the three-dimensional knitted fabric formed by plastic deformation due to heat and pressure, where fibers are fused together, or a thinner region formed by embroidery or sewing. Regions whose thickness decreases following these thinner regions are not included in the concave deformable portions. Concave deformable portions formed by fusing fibers together are typically formed by hot stamping. Concave deformable portions formed by embroidery or sewing can be formed using any yarn and method, and can be formed using embroidery sewing machines, flat sewing machines, zigzag sewing machines, etc., depending on the pattern and stitch shape. From the viewpoint of suppressing pilling caused by protrusions, concave deformable portions are preferably formed by fusing fibers together; from the viewpoint of improving cushioning by suppressing lateral tilting, concave deformable portions are preferably formed by embroidery or sewing.

[0037] For the three-dimensional woven fabric of the seat cover material constituting this embodiment, the parameter A calculated by the following formula needs to be 6 or more and 36 or less:

[0038] Parameter A = Coil row density (coil row / 2.54cm) × concave thickness (mm) / fabric thickness (mm).

[0039] If parameter A is less than 6, the surface loops are rough, and the thickness variation from the non-deformable part to the deformable part increases. Therefore, the contact area during compression decreases, causing pressure to concentrate. As a result, the hooks and other protrusions of the hook and loop fasteners easily snag on the individual fibers of the surface loops, cutting them and causing pilling. Conversely, when parameter A exceeds 36, although the hooks and other protrusions of the hook and loop fasteners are less likely to snag on the individual fibers of the surface loops, the surface becomes smooth. Therefore, it is not possible to prevent the seated person's buttocks from sliding. In addition, the angle formed by the connecting thread that connects the two layers of knitted fabric and the fabric thickness direction becomes smaller. Furthermore, the connecting thread is not fixed in the concave deformable part, so it is not possible to prevent lateral tilting, resulting in poor cushioning.

[0040] From the viewpoint of suppressing pilling caused by protrusions, the preferred range for parameter A is 8 or more, and more preferably 10 or more. Furthermore, from the viewpoint of suppressing the sliding of the seated person's buttocks and improving cushioning by suppressing lateral tilting, the preferred range for parameter A is 30 or less, and more preferably 24 or less.

[0041] To ensure that parameter A is 6 or higher and 36 or lower, it is preferable to adjust the fineness of the fibers used in weaving three-dimensional knitted fabrics, the knitting machine gauge, the loop rows on the machine, the knitting structure, and the shrinkage rate, stretching rate, overfeed rate, and underfeed rate during finishing processes such as heat setting. When forming a concave deformed portion on the surface side of the three-dimensional knitted fabric, in the case of deformation caused by heat, it is preferable to adjust the heating time, the temperature of the pressure table, the shape of the pressing die, the temperature of the pressing die, and the pressing pressure. Low-melting-point yarns and heat-bonded yarns can also be used. When using other deformation forming methods, the concave portion can also be formed by embroidery. In this case, it is preferable to adjust the type of sewing thread, fineness, embroidery pattern, sewing machine needle, sewing width, and stitch spacing.

[0042] Lateral tipping is prone to occur during compression of three-dimensional knitted fabrics due to the movement of the outer knitted layer relative to the inner knitted layer along the warp direction. In the three-dimensional knitted fabric constituting the seat cover material of this embodiment, the concave deformation portion is preferably formed over 5 or more consecutive warp rows, more preferably over 10 or more warp rows. If it is formed over 5 or more warp rows, it is easier to prevent the outer knitted layer from moving along the warp direction using the concave deformation portion, and it is easier to suppress lateral tipping.

[0043] In the three-dimensional woven fabric of the seat cover material constituting this embodiment, the concave deformation portion is preferably continuously formed on the same coil longitudinal row for 60 or fewer coil rows, more preferably for 40 or fewer coil rows. If the concave deformation portion is continuously formed on the same coil longitudinal row for 60 or fewer coil rows, it is less likely that the cushioning during sitting will be reduced due to localized changes in the compression characteristics caused by the concave deformation portion.

[0044] When the three-dimensional knitted fabric constituting the seat cover material of this embodiment has multiple concave deformable portions, the warp spacing of the knitted fabric between the closest concave deformable portions on the same loop is preferably 10 mm or more and less than 300 mm, more preferably 15 mm or more and less than 250 mm. If the warp spacing of the knitted fabric between the concave deformable portions is 10 mm or more, it is easier to suppress the reduction of cushioning between the concave deformable portions. In addition, since the curvature of the convex portions between the concave deformable portions increases, it is easier to suppress pilling caused by protrusions. On the other hand, if the warp spacing of the knitted fabric between the concave deformable portions is less than 300 mm, it is particularly effective to suppress the movement of the surface knitted fabric between the concave deformable portions along the knitted fabric warp direction, and it is easier to suppress lateral tilting.

[0045] In the three-dimensional woven fabric of the seat cover material constituting this embodiment, the loop density of the knitted fabric that forms the seat surface side of the seat cover material is preferably 11,500 or more and 20,000 or less.

[0046] In this specification, the term "loop density" is an indicator of the density of the loops in the surface knitted fabric, expressed by the following formula:

[0047]

[0048] {In the formula, N is the number of loops in the surface knitted fabric per 2.54 cm square, and D is the total fineness (decibels) of the fibers forming one loop in the surface knitted fabric}. Furthermore, "the total fineness of the fibers forming one loop in the surface knitted fabric" refers to the total fineness of the fibers that form loops only, excluding fibers that do not form loops, such as those used in weaving or other interpolation techniques.

[0049] If the coil density is above 11500, the hooks and other protrusions of the hook and loop fastener will not easily snag on the single fibers of the surface coil, and the single fibers will not be cut, thus making it less prone to pilling.

[0050] From the viewpoint of suppressing fuzzing caused by protrusions, the coil density range is more preferably 13,000 or more and 23,000 or less, and even more preferably 14,000 or more and 23,000 or less.

[0051] In order to set the coil density to be above 11,500 and below 23,000, it is preferable to adjust the fineness of the fibers used in the surface knitted fabric, the knitting machine number, the loop row on the machine, the knitting structure, and the shrinkage rate, stretching rate, overfeed rate, and underfeed rate in finishing processes such as heat setting.

[0052] The raw materials used for the surface knitted fabric are not limited; they can be a single raw material or a combination of multiple raw materials through blending, twisting, mixing, or interweaving. However, considering the strength and light resistance of the raw yarn, long fibers of polyethylene terephthalate (PET) are preferred. Furthermore, from the perspective of increasing the pull-out resistance of individual fibers to prevent them from being pulled out of the knitted fabric surface due to protrusions such as hooks on hook-and-loop fasteners, PET fibers are preferably false-twist yarns, interwoven yarns, or twisted yarns.

[0053] The fineness of the fibers used in the surface knitted fabric is preferably 100 dtex or more and 350 dtex or less, based on the principle of appropriate loop density. Furthermore, from the same perspective, the total fineness of one loop formed from the fibers constituting the surface knitted fabric is preferably 150 dtex or more and 800 dtex or less.

[0054] In addition, when the fiber used in the surface knitted fabric is multifilament, its monofilament fineness is preferably 1 dtex or more and 6 dtex or less, more preferably 3 dtex or more and 6 dtex or less with higher monofilament strength.

[0055] The fiber used for the connecting yarn is preferably a monofilament. When a monofilament is used for the connecting yarn, its fineness is preferably 30 dtex or more and 300 dtex or less, more preferably 50 dtex or more and 250 dtex or less, while suppressing the monofilament from protruding onto the surface of the knitted fabric and maintaining good cushioning.

[0056] If the monofilament protrudes from the surface of the knitted fabric in a three-dimensional knit, it is easily caught by protrusions such as the hooks of hook and loop fasteners. Therefore, it is preferable to press the loops of the fibers forming the surface knitted fabric into the loops of the monofilament in a manner where the monofilament does not protrude from the outer side of the knitted fabric (i.e., the seat surface of the seat cover material). For this purpose, the fineness D2 (denier) of the monofilament preferably satisfies the following relationship with respect to the total fineness D1 (denier) of one loop formed by the fibers forming the surface knitted fabric:

[0057] D1 / D2≥3.

[0058] The fibers constituting the three-dimensional woven fabric can be made from any raw materials, and various fiber raw materials can be combined. However, considering the ease of recycling such as material recycling and chemical recycling, the outer knitted fabric, connecting yarn, and inner knitted fabric are preferably all 100% polyethylene terephthalate (PET) fibers. These fibers can be undyed, and solution-dyed or pre-spinning-dyed yarns are preferred while suppressing the quantitative changes in the three-dimensional woven fabric during dyeing. Furthermore, solution-dyed yarns incorporating pigments or the like are even more preferred, as they do not require a dyeing process.

[0059] The thickness of the three-dimensional woven fabric constituting the seat cover material of this embodiment can be arbitrarily set. From the viewpoint of sewing properties, processability, and cushioning properties as a cover material, it is preferably 3mm or more and 12mm or less, more preferably 3mm or more and 8mm or less. In addition, the weight per unit area of ​​the three-dimensional woven fabric can be arbitrarily set, preferably 400 to 1000 g / m². 2 More preferably, it is 500–900 g / m 2 .

[0060] In the finishing method of the three-dimensional woven fabric constituting the seat cover material of this embodiment, when using three-dimensional woven fabrics with pre-dyed yarns or solution-dyed yarns, the greige fabric can be finished through processes such as scouring and heat setting. However, from the perspective of process simplification, it is more preferable to finish the fabric only through heat setting. When either the connecting yarn or the fiber used in the outer and inner knitted layers is an undyed three-dimensional woven fabric, the greige fabric can be finished through processes such as pre-setting, scouring, dyeing, and heat setting.

[0061] The seat upholstery material of this embodiment is used in seats and can be laminated with polyurethane on the back of the seating surface, as is the case with conventional seat upholstery materials. However, from the perspective of recyclability, it is preferable to use it without lamination. The seat upholstery material of this embodiment can be composed of a three-dimensional woven fabric alone, but from the perspective of design and functionality, it can also be composed of other raw materials through sewing or other methods.

[0062] Example

[0063] The present invention will be described in more detail below through examples and comparative examples, but the present invention is not limited to the examples.

[0064] The methods for measuring various properties of the three-dimensional woven fabrics used in the following examples are described below.

[0065] (a) Parameter A

[0066] The loop density of the three-dimensional woven fabric (number of loops / 2.54cm) is measured visually. Additionally, the thickness (mm) of the concave deformed portions and the thickness (mm) of the non-deformed portions are measured. Here, in cases where the three-dimensional woven fabric has multiple concave deformed portions of varying thickness, and where the thickness varies due to the location of the concave deformed portions, the portion with the smallest thickness is defined as the concave portion thickness. Furthermore, for the fabric thickness, the thickness of the portion where the concave deformed portions have the least impact on the fabric thickness is measured. In other words, the portion where the thickness of the three-dimensional woven fabric is the largest is defined as the fabric thickness. The thickness is measured using a thickness gauge under a pressure of 0.7 kPa. Furthermore, for the thickness of the concave deformed portions, the thickness is measured when the pressure is applied only to the concave deformed portions.

[0067] As described above, using the measured coil row density, the thickness of the concave deformation section, and the fabric thickness, parameter A is calculated using the following formula:

[0068] Parameter A = Coil row density (coil row / 2.54cm) × concave thickness (mm) / fabric thickness (mm).

[0069] (b) Loop density of the surface knitted fabric

[0070] A filament is drawn from the surface knit of the three-dimensional knitted fabric, and the total fineness D (denier) of the fibers forming one loop of the surface knit is measured. At this point, no connecting fibers are present. Additionally, the loop density N of the three-dimensional knitted fabric is calculated using the following formula: (The formula is not provided in the original text.)

[0071]

[0072] (c) The number of longitudinal rows of coils with concave deformation sections

[0073] Cut the three-dimensional woven fabric to a size of 40cm × 40cm, randomly select one concave deformation section, and visually count the number of coil rows forming the concave deformation section. At this time, when the concave deformation section is formed across multiple coil rows, do not only count the number of coil rows on the same coil row, but count the total number of coil rows across multiple coil rows.

[0074] In addition, when the concave deformation section covers the entire width of the cut three-dimensional knitted fabric, the number of loops in the entire width of the three-dimensional knitting is taken as the number of loops in the concave deformation section.

[0075] (d) The number of coil rows on the same longitudinal row where the concave deformation is formed

[0076] Cut the three-dimensional woven fabric to a size of 40cm×40cm, randomly select one concave deformation part, and visually count the number of horizontal rows of the same coil in the same coil column that forms the concave deformation part.

[0077] (e) The knitted fabrics with the closest concave deformed sections on the same loop warp spacing are interposed.

[0078] Cut the three-dimensional knitted fabric into 40cm×40cm pieces, extract the closest concave deformed sections on the same loop warp, and use a ruler to visually measure the warp spacing of the knitted fabric between these concave deformed sections.

[0079] (f) Lining caused by hook and loop fasteners (grade)

[0080] Using a planar abrasion testing machine manufactured by Daiei Scientific Instruments, a 3D woven fabric measuring 8cm wide and 31cm long was placed on the planar abrasion table of the machine with the surface knitted fabric facing up, and both ends were secured with clamps. Next, a Magic Tape (registered trademark) A8693Y.71 (5cm long) manufactured by Kuraray Fastening Co., Ltd. was attached to the friction piece with the hook side facing outwards. Including the friction piece, the pressing load was set to 9.8N, the stroke to 14cm, and the speed to 60±10 reciprocating strokes / minute. The friction piece was loaded onto the test piece, and an abrasion test was performed for 5 reciprocating cycles. Measurements were taken from the longitudinal and transverse directions of the woven fabric. After the test, the abrasion condition of the test piece surface was observed, and a grade was determined according to the following criteria: Grades were determined in increments of 0.5.

[0081] Level 5: No fuzzing detected

[0082] Level 4: Slight fuzzing detected

[0083] Grade 3: Obvious fuzzing is observed, but head breakage is not significant.

[0084] Level 2: Slightly noticeable fuzzing, with broken ends and "pulled-out" fibers.

[0085] Grade 1: Significant pilling and severely abnormal appearance

[0086] (g) Buffering

[0087] The outer material is laid on the polyurethane padding of the seat and back of the car seat, creating a seat where the entire surface in contact with the human body is made of an outer material formed by three-dimensional weave.

[0088] The following criteria were used to rate how well the testers sitting in this seat perceived the cushioning, serving as an evaluation of the cushioning performance. The rating is based on a scale of 0.5.

[0089] Level 5: Reliable cushioning, comfortable.

[0090] Level 4: Provides some cushioning, offering a slightly comfortable experience.

[0091] Level 3: Slightly cushioned, but uncomfortable.

[0092] Level 2: There is some buffer, but it's slightly uncomfortable.

[0093] Level 1: No cushioning, uncomfortable

[0094] (h) Slippage

[0095] The following criteria were used to rate how well testers sitting in the chair perceived the smoothness of the cushioning, as an evaluation of its cushioning properties. The rating was based on a scale of 0.5.

[0096] Level 5: Not slippery at all, excellent grip.

[0097] Level 4: Minimal slipperiness, feels grippy

[0098] Level 3: Slightly less slippery

[0099] Level 2: Slightly slippery, didn't feel much grip.

[0100] Level 1: Extremely slippery, with absolutely no sense of grip.

[0101] (i) Lateral tilting

[0102] The surface material, cut into squares with sides of 40cm, is placed on a horizontal table with the surface facing up. The lateral tilting resistance when pressed down from above is graded using the following benchmark. The lateral tilting resistance is assessed in increments of 0.5.

[0103] Level 5: Not tilting laterally at all

[0104] Level 4: Slightly tilted laterally

[0105] Level 3: Lateral tilt

[0106] Level 2: Leaning rather horizontally

[0107] Level 1: Extremely prone to tipping over laterally and does not recover its shape after compression.

[0108] [Examples 1 to 7]

[0109] Using a 22-gauge double Raschel warp knitting machine equipped with 6 reeds and 6mm between needle cylinders, two reeds (L1, L2) forming the outer knitted fabric are fed with two false-twisted filaments of 167dtex 48 filament polyethylene terephthalate (black solution-dyed yarn) in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement. One reed (L3) forming the connecting part is fed with a 1-out-1-in (L3) arrangement of 110dtex polyethylene terephthalate (black solution-dyed yarn) monofilament. Then, two reeds (L5, L6) forming the inner knitted fabric are fed with false-twisted filaments of 167dtex 48 filament polyethylene terephthalate (black solution-dyed yarn) in a full-in arrangement to knit a three-dimensional woven fabric.

[0110] Using the knitting structure shown below, with the machine loops set to 33 loop rows / 2.54cm, a three-dimensional woven fabric is woven. The resulting fabric is stretched by 1%, and after dry heat setting at 175°C for 1 minute with an overfeed rate of 0%, it is hot-pressed from the surface side at a pressing die with the design shown below at a pressing die temperature of 200°C for 6 seconds to obtain a three-dimensional woven fabric with concave deformed sections having various physical properties as shown in Table 1 below. These fabrics are used as seat upholstery materials.

[0111] (Knitted structure)

[0112] L1: 1011 / 2322 / (1 in, 1 out)

[0113] L2: 2322 / 1011 / (1 out, 1 in)

[0114] L3: 3410 / 4367 / (1 out, 1 in)

[0115] L4: — (No wire feeding.)

[0116] L5: 0001 / 1110 / (All In)

[0117] L6: 2234 / 2210 / (All In)

[0118] (Pressure molding die design)

[0119] Example 1: Refer to Figure 1 (W1: 1mm, W2: 12mm)

[0120] Example 2: Refer to Figure 1 (W1: 2mm, W2: 16mm)

[0121] Example 3: Reference Figure 1 (W1: 7mm, W2: 38mm)

[0122] Example 4: Reference Figure 2 (W3: 5mm, W4: 5mm, W5: 5mm, W6: 5mm)

[0123] Example 5: Refer to Figure 3 (W7: 35mm, W8: 35mm, W9: 70mm, W10: 60mm, W11: 60mm)

[0124] Example 6: Refer to Figure 1 (W1: 50mm, W2: 60mm)

[0125] Example 7: Refer to Figure 2 (W3: 8mm, W4: 8mm, W5: 12mm, W6: 12mm)

[0126] Example 8: Refer to Figure 4 (W12: 1mm, W13: 12mm)

[0127] Figures 1-4 The white areas are recessed areas on the pressing mold, while the black areas are convex areas. In other words, a concave deformed area with the same shape as the black area in the diagram is formed on the three-dimensional knitted fabric. Furthermore, Figures 1-4 The term "repeating unit" indicates the number of repeating units in the pressing die, and does not limit the number of concave deformed portions. In this embodiment and the comparative example, Figures 1-4 The concave deformation section shown is repeatedly formed in both the warp and weft directions of the knitted fabric. Additionally, to make... Figures 1-4 The fabric was pressed in a manner that aligned the vertical direction with the warp direction of the three-dimensional knitted fabric.

[0128] [Example 9]

[0129] The false-twisted yarn of polyethylene terephthalate fiber (black solution-dyed yarn) with a length of 222 dtex 48 is fed from the two reeds (L1, L2) forming the surface knitted fabric. The machine loop row is set to 24 loop rows / 2.54 cm. Otherwise, similar to Example 1, a three-dimensional woven fabric with concave deformation part having various physical properties as shown in Table 1 is obtained and used as a seat cover material.

[0130] [Example 10]

[0131] The machine coil rows are set to 38 coil rows / 2.54cm. Otherwise, similar to Example 9, a three-dimensional woven fabric with concave deformable parts with various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0132] [Example 11]

[0133] After heat setting, no hot pressing process was performed; instead, the process was carried out by... Figure 1 The blackened part is embroidered to form a concave deformed part. In addition, similar to Example 1, a three-dimensional woven fabric with concave deformed parts with various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0134] [Example 12]

[0135] After heat setting, no hot pressing process was performed; instead, the process was carried out by... Figure 2 The blackened part is embroidered to form a concave deformed part. In addition, similar to Example 4, a three-dimensional woven fabric with concave deformed parts with various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0136] [Example 13]

[0137] After heat setting, no hot pressing process was performed; instead, the process was carried out by... Figure 3 The blackened part is embroidered to form a concave deformed part. In addition, similar to Example 5, a three-dimensional woven fabric with concave deformed parts with various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0138] [Example 14]

[0139] After heat setting, no hot pressing process was performed; instead, the process was carried out by... Figure 4 The blackened part is embroidered to form a concave deformed part. In addition, similar to Example 8, a three-dimensional woven fabric with concave deformed parts having various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0140] [Example 15]

[0141] After heat setting, no hot pressing process was performed; instead, the process was carried out by... Figure 1 The blackened part is embroidered to form a concave deformed part. In addition, similar to Example 9, a three-dimensional woven fabric with concave deformed parts having various physical properties as shown in Table 2 is obtained and used as a seat cover material.

[0142] [Comparative Example 1]

[0143] The pressing mold temperature was set to 220°C and the pressing time was set to 10 seconds. Otherwise, similar to Example 9, a three-dimensional woven fabric with concave deformable parts having various physical properties as shown in Table 2 was obtained and used as a seat cover material.

[0144] [Comparative Example 2]

[0145] The pressing mold temperature was set to 120°C and the pressing time was set to 3 seconds. Otherwise, similar to Example 10, a three-dimensional woven fabric with concave deformable parts with various physical properties as shown in Table 2 was obtained and used as a seat cover material.

[0146] [Table 1]

[0147]

[0148] [Table 2]

[0149]

[0150] As shown in Tables 1 and 2, in the seat cover materials of Examples 1 to 15, which include three-dimensional woven fabrics with concave deformable parts containing parameter A of 6 or more and 36 or less, the pilling caused by hook and loop fasteners (hook side), the lateral tilting phenomenon during compression, and the sliding of the seat part are all suppressed, and the cushioning is good.

[0151] In contrast, in Comparative Example 1, where parameter A is less than 6, the cushioning is good, and lateral tipping and slippage are suppressed, but the fuzzing caused by the hook and loop fastener is significantly lower.

[0152] In addition, in Comparative Example 2, parameter A was 39, which was too high. Although the fuzzing caused by the hook and loop fastener was suppressed, it failed to suppress lateral tilting and slippage.

[0153] Industrial availability

[0154] The seat cover material of the present invention is a seat cover material that can be disposed on a cushioning member such as a polyurethane pad in the seat of a vehicle, furniture or the like to form a seat, or formed by being stretched on a chair frame to form a lightweight and thin seat. It is suitable for seat cover materials that have high cushioning properties and can suppress the generation of pilling even when rubbed by hard protrusions such as hooks of hook and loop fasteners, and can also suppress slippage when sitting.

Claims

1. A seat upholstery material, the seat surface of which is composed of a three-dimensional woven fabric, the three-dimensional woven fabric comprising: two knitted layers, having an outer layer and an inner layer; and connecting yarns that connect the two knitted layers to each other, characterized in that, The three-dimensional woven fabric has concave deformable portions on the surface side, and all the concave deformable portions have the same shape. The parameter A calculated by the following formula is greater than 6 and less than 36: Parameter A = Coil row density × Recess thickness / Fabric thickness, where the coil row density is coil rows / 2.54cm, and the units for the recess thickness and the fabric thickness are mm. The total fineness of the fibers forming one loop of the knitted fabric on the surface is 150 dtex or more and 800 dtex or less, and, The warp density of the surface knitted fabric is between 22 warp counts / 2.54cm and 25 warp counts / 2.54cm, and... The stitch density of the surface knitted fabric is more than 25 stitches per 2.54 cm and less than 41 stitches per 2.54 cm. The knitted fabric that makes up the surface layer is made of polyethylene terephthalate. This three-dimensional woven fabric is woven using a double Raschel warp knitting machine. The concave deformation portion is formed over five or more consecutive longitudinal rows of coils.

2. The seat upholstery material according to claim 1, wherein, The concave deformation portion is continuously formed on the same coil longitudinal row, covering 60 coil rows and below.

3. The seat upholstery material according to claim 1 or 2, wherein, The three-dimensional woven fabric has multiple concave deformable portions, and the closest concave deformable portions on the same coil longitudinal row are spaced more than 10 mm and less than 300 mm apart.

4. The seat upholstery material according to claim 1 or 2, wherein, The closest concave deformations on the same longitudinal row of coils are spaced more than 15 mm and less than 300 mm apart.

5. The seat upholstery material according to claim 1 or 2, wherein, The concave deformation portion is formed by fusing fibers together.

6. The seat upholstery material according to claim 4, wherein, The concave deformation portion is formed by fusing fibers together.

7. The seat upholstery material according to claim 1 or 2, wherein, The concave deformed portion is formed by embroidery or sewing.

8. The seat upholstery material according to claim 1 or 2, wherein, The coil density of the surface layer of the three-dimensional braided fabric is above 11,500 and below 23,000.

9. The seat upholstery material according to claim 8, wherein, The coil density of the surface layer of the three-dimensional braided fabric is above 13,000 and below 23,000.

10. The seat upholstery material according to claim 1 or 2, wherein, The thickness of the three-dimensional woven fabric is more than 3 mm and less than 12 mm.

11. The seat upholstery material according to claim 1 or 2, wherein, The weight per unit area of ​​the three-dimensional woven fabric is 400–1000 g / m². 2 .

12. A type of seat, wherein, The seat comprises the seat cover material as described in claim 1 or 2.

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