A 3D fabric structure

Abstract

A 3D fabric structure belongs to the technical field of spacer fabrics. It includes a surface fabric and a bottom fabric and a middle yarn used to braid and connect the surface fabric and the bottom fabric. The surface fabric is formed with a surface fabric through hole, the bottom fabric has a bottom fabric through hole, the surface fabric through hole has four surface fabric through hole corners, the bottom fabric through hole has four bottom fabric through hole corners, the surface and bottom fabric through hole corners correspond to each other up and down, the surface fabric through hole corners of adjacent surface fabric through holes are shared, the bottom fabric through hole corners of adjacent bottom fabric through holes are shared, and the surface and bottom fabric through hole corners correspond to each other up and down. The characteristic is that the middle yarn is braided and connected between the opposite sides of the surface fabric through hole corner and the bottom fabric through hole corner, so that the surface fabric and the bottom fabric jointly form the first, second, third, fourth and fifth channels for ventilation. Advantages: significantly improve the ventilation effect, save the middle yarn raw materials, and improve the rigidity, and avoid the collapse under pressure during use to affect the recovery.

Description

Technical Field

[0001] The invention belongs to the technical field of spacer fabrics, and in particular relates to a 3D fabric structure. Background Art

[0002] The aforementioned 3D fabric refers to a fabric composed of a surface layer, i.e., the upper layer, a bottom layer, i.e., the lower layer, and a middle yarn connecting the surface layer and the bottom layer. This fabric has good ventilation and air permeability as well as a soft and elastic effect and is widely used in mattresses, upholstered furniture, vehicle interiors, seats, etc.

[0003] Technical information related to the aforementioned 3D fabrics can be found in the published Chinese patent documents, such as CN112680863B recommending "a 3D fabric and a method for preparing the same", CN217298198U providing "a 3D fabric", and CN108606544A introducing "three-dimensional mesh structure", etc. Typical examples include "spacer knitted fabric and method for manufacturing spacer knitted fabric" disclosed by German Miller Textile Co., Ltd. CN106133225A and "spacer knitted fabric and method for manufacturing spacer knitted fabric segments" also published by German Miller Textile Co., Ltd. CN105324525A.

[0004] The above CN106133225A and CN105324525A are both composed of an upper layer as a surface tissue, a lower layer as a bottom tissue, and a middle yarn connected between the upper and lower layers. Specifically, the spacer knitted fabric provided by CN105324525A includes a planar first knitted fabric layer and a planar second knitted fabric layer, the first knitted fabric layer and the second knitted fabric layer are connected to each other by woven spacer yarns, wherein the first knitted fabric layer has openings respectively composed of a plurality of coils, the yarns of the first yarn system constituting the first knitted fabric layer are connected to each other only by being entangled with each other, and a channel is formed between each knitted fabric layer, and the channel does not have spacer yarns, and the technical key points of the patent are: the yarns of the second yarn system constituting the second knitted fabric layer are connected to each other by being entangled and at least partially fused. By analyzing the specification of the patent, it can be determined that it is a kind of spacer knitted fabric woven by the first and second knitted fabric layers and the spacer yarn, which has channels in the three directions of X, Y and Z, so as to reflect the ventilation effects in three aspects. However, from the schematic diagrams of the last two figures of the patent and the descriptions in paragraphs 0057 to 0068 of its specification, it is not difficult to find that there are still the following shortcomings: First, due to the unreasonable structure of the overall spacer knitted fabric, the channels are limited to the X, Y and Z directions, and the number of channels cannot be expanded or increased, which has a certain restrictive effect on the expectation of obtaining a more ideal ventilation effect; second, because the spacer yarns connecting the first and second knitted fabric layers are continuously distributed between the first and second knitted fabric layers, it is very unfavorable for saving the raw materials of the spacer yarns, and it is also accompanied by the disadvantage of affecting ventilation; third, due to the unreasonable arrangement position of the spacer yarns, the reasonable compressive strength or reasonable rigidity of the spacer knitted fabric will be fragile, and it is easy to collapse after being compressed, which affects the recovery effect. Summary of the invention

[0005] The task of the present invention is to provide a 3D fabric structure which helps to increase channels and thus significantly improve the air permeability and ventilation effects, is beneficial to improving the connection structure between the middle yarn as the spacer yarn and the surface tissue and the bottom tissue and thus significantly saves the middle yarn raw materials, and is beneficial to improving the rigidity and thus avoiding the collapse due to pressure during use and affecting the recovery.

[0006] The task of the present invention is accomplished in this way: a 3D fabric structure comprises a surface fabric and a bottom fabric and a middle yarn for knitting and connecting the surface fabric and the bottom fabric, wherein the surface fabric is constituted with a surface fabric through hole, and the bottom fabric is constituted with a bottom fabric through hole, the surface fabric through hole and the bottom fabric through hole are of the same size and correspond to each other up and down, and are respectively constituted on the surface fabric and the bottom fabric with unlimited length and width in the same state, both at intervals and continuously and repeatedly, wherein the surface fabric through hole has four surface fabric through hole corners, and the bottom fabric through hole has four bottom fabric through holes. The through-hole corners are woven, the through-hole corners of the surface tissue and the bottom tissue correspond to each other up and down, and the surface tissue through-hole corners of adjacent surface tissue through holes are shared, and the bottom tissue through-hole corners of adjacent bottom tissue through holes are also shared, and the surface and bottom tissue through-hole corners correspond to each other up and down, and are characterized in that the middle silk is woven and connected between the opposite sides of the through-hole corners of the surface tissue and the through-hole corners of the bottom tissue so that the surface tissue and the bottom tissue jointly form a first channel I, a second channel II, a third channel III, a fourth channel IV and a fifth channel V for ventilation.

[0007] In a specific embodiment of the present invention, the number of the middle filaments braided and connected between the opposite sides of the corner of the surface tissue through hole and the corner of the bottom tissue through hole is four.

[0008] In another specific embodiment of the present invention, the middle filaments are at least partially fused and connected at the braided connections at the corners of the surface tissue through holes and the corners of the bottom tissue through holes, respectively.

[0009] In yet another specific embodiment of the present invention, the surface tissue through holes of the surface tissue and the bottom tissue through holes of the bottom tissue are quadrilateral holes.

[0010] In another specific embodiment of the present invention, the quadrilateral hole is a diamond hole, and the side length of the diamond hole is 0.6-1.2 mm.

[0011] In yet another specific embodiment of the present invention, the surface tissue and the bottom tissue are each woven from four mixed yarns of 300D / 96F DTY yarns and 840D / 384F FDY yarns.

[0012] In a more specific embodiment of the present invention, the mass percentage of the 300D / 96F DTY yarn in the surface tissue and the bottom tissue is 60%, and the mass percentage of the 840D / 384F FDY yarn in the surface tissue and the bottom tissue is 40%.

[0013] In a further specific embodiment of the present invention, the polyester monofilament used as the middle filament is solid, and its cross-sectional shape is circular.

[0014] In yet another specific embodiment of the present invention, the diameter of the polyester monofilament used as the middle filament is 0.25-0.32 mm.

[0015] In yet another specific embodiment of the present invention, the 3D fabric composed of the surface tissue, the bottom tissue and the middle yarn woven and connected between the surface tissue and the bottom tissue has a gram weight of 380-520 g / m 2 .

[0016] The technical effect of the technical solution provided by the present invention is that since the middle yarn is woven and connected only between the opposite sides of the corners of the through holes of the surface and bottom tissues, the surface and bottom tissues can jointly form a first channel I, a second channel II, a third channel III, a fourth channel IV and a fifth channel V with air permeability and ventilation. Compared with the existing technology, it helps to increase the channels and significantly improve the air permeability and ventilation effect, is beneficial to saving the middle yarn raw materials, and is beneficial to improving the rigidity to avoid the impact of recovery due to pressure collapse during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a structural diagram of an embodiment of the present invention;

[0018] Figure 2 for Figure 1 Schematic diagram of the surface organization shown;

[0019] Figure 3 for Figure 1 Detailed structural diagram showing the connection between the surface tissue and the bottom tissue in the middle silk weaving. DETAILED DESCRIPTION

[0020] In order to more clearly understand the technical essence and beneficial effects of the present invention, the applicant provides a detailed description in the form of embodiments below. However, the description of the embodiments is not a limitation of the present invention. Any equivalent changes made based on the concept of the present invention that are merely formal and not substantial should be regarded as within the scope of the technical solution of the present invention.

[0021] In the following description, all concepts related to directionality or orientation such as up, down, left, right, front and back are based on the position state of the figure as an example, and therefore cannot be understood as a special limitation on the technical solution provided by the present invention. Example 1

[0022] See also Figures 1 to 3 , showing the surface tissue 1 and the bottom tissue 2 and the middle silk 3 (also called middle silk tissue or intermediate tissue) used to weave the surface tissue 1 and the bottom tissue 2 together. The surface tissue 1 and the bottom tissue 2 referred to here are only based on Figure 1The present invention is not limited to the position state, and therefore cannot be understood as limiting the present invention. For example, when flipped 180°, the bottom tissue 2 is swapped with the surface tissue 1. In addition, the surface tissue 1 can also be called the first fabric layer, and the bottom tissue 2 can also be called the second fabric layer or other similar definitions. Therefore, the expression of technical language should not be limited by the expression of technical terms used in the present invention. The surface tissue 1 is composed of surface tissue through holes 11 formed by weaving, and the bottom tissue 2 is composed of bottom tissue through holes 21 formed by weaving. The surface tissue through holes 11 and the bottom tissue through holes 21 are the same size and correspond to each other up and down and are both spaced and continuous in the same state. It is repeatedly constructed on a surface structure 1 and a bottom structure 2 whose length and width (the width depends on the specifications and / or process requirements of the double needle bed warp knitting machine) are not limited, wherein the surface structure through hole 11 has four surface structure through hole corners 111, and the bottom structure through hole 21 has four bottom structure through hole corners 211, the surface and bottom structure through hole corners 111, 211 correspond to each other up and down, and the surface structure through hole corners 111 of adjacent surface structure through holes 11 are shared, and the bottom structure through hole corners 211 of adjacent bottom structure through holes 21 are also shared, and the surface and bottom structure through hole corners 111, 211 correspond to each other up and down.

[0023] The technical key points of the technical solution provided by the present invention are as follows: the aforementioned middle silk 3 is woven and connected between the opposite sides of the aforementioned surface tissue through-hole corner 111 and the bottom tissue through-hole corner 211 so that the aforementioned surface tissue 1 and the bottom tissue 2 together form a first channel Ⅰ4, a second channel Ⅱ5, a third channel Ⅲ6, a fourth channel Ⅳ7 and a fifth channel Ⅴ8 for air permeability and ventilation.

[0024] The knitting mentioned above is weaving. In this embodiment, the surface structure 1, the bottom structure 2 and the middle silk 3 are woven into a double needle bed warp knitting process. Figure 1 As the double needle bed warp knitting process of the 3D fabric structure shown is a mature and well-known process, the applicant will not elaborate on it any more.

[0025] Depend on Figure 1 and Figure 2 As shown, the first channel I4 indicated by the arrow from left to right, the second channel II5 indicated by the arrow from back to front, the third channel III6 indicated by the arrow from left to right and at an angle of 45 degrees, the fourth channel IV7 indicated by the arrow from top to bottom and also at an angle of 45 degrees, and the fifth channel V8 indicated by the arrow from bottom to top longitudinally can jointly achieve the excellent ventilation effect of the five channels, because, compared with the existing technology such as CN105324525A, the third channel III6 and the fourth channel IV7 are added, and the number of channels is proportional to the quality of the ventilation effect, that is, the more channels, the better the ventilation effect, and vice versa.

[0026] In this embodiment, the number of the aforementioned middle yarns 3 woven and connected between the aforementioned through hole corners 111 of the surface tissue and the through hole corners 211 of the bottom tissue is four solid polyester monofilaments with a circular cross-sectional shape and a diameter of 0.28-0.29 mm in the range of 0.25-0.32 mm. The number of the middle yarns is determined to be four because the inventor of the present application has found a reasonable balance point between rigidity, elastic recovery (recovery), air permeability and saving of middle yarn raw materials through a non-limited number of tests and records made during the tests.

[0027] The aforementioned middle silk 3 is at least partially fused and connected at the braided connection of the aforementioned surface tissue through hole corner 111 and the bottom tissue through hole corner 211, and this partial fusion connection (also called "bonding") is completed simultaneously during the weaving process.

[0028] The surface tissue through hole 11 of the surface tissue 1 and the bottom tissue through hole 21 of the bottom tissue 2 are quadrilateral holes and rhombus holes. The side length of the rhombus hole is preferably 0.6-1.2mm, preferably 0.7-1.1mm, more preferably 0.8-1mm, and most preferably 0.9mm. 0.9mm is selected in this embodiment.

[0029] In this embodiment, the surface tissue 1 and the bottom tissue 2 are each composed of four 300D / 96F DTY yarns and 840D / 384F FDY mixed yarns (also called "composite yarns"), wherein the mass percentages of the 300D / 96F DTY yarns and the 840D / 384F FDY yarns in the surface tissue 1 and the bottom tissue 2 are 60% and 40% respectively, that is, the mass percentages of the 300D / 96F DTY yarns in the surface tissue 1 and the bottom tissue 2 are both 60%, and the mass percentages of the 840D / 384F FDY yarns in the surface tissue 1 and the bottom tissue 2 are both 40%.

[0030] As mentioned above, the 3D fabric structure of the present invention is woven by a double needle bed warp knitting machine, and the warp drawing method is briefly described as follows: the aforementioned yarn constituting the surface structure 1 is composed of 840D / 384F FDY yarn, and the comb L2 is composed of 300D / 96F DTY yarn; the aforementioned polyester yarn constituting the middle yarn 3 is composed of comb L3 and comb L4; and the aforementioned yarn constituting the bottom structure 2 is composed of 300D / 96F DTY yarn, and the comb L6 is composed of 840D / 384F FDY yarn.

[0031] The 3D fabric of this embodiment, which is composed of the surface tissue 1, the bottom tissue 2 and the middle yarn 3 woven and connected between the surface tissue 1 and the bottom tissue 2, has a gram weight of 420 g / m 2 . Example 2

[0032] Only the diameter of the middle yarn 3 was changed to 0.25-0.26 mm, and the weight of the obtained 3D fabric was 380 g / m 2 The rest is the same as the description of Example 1. Example 3

[0033] Only the diameter of the middle yarn 3 was changed to 0.31-0.32 mm, and the weight of the obtained 3D fabric was 520 g / m 2 The rest is the same as the description of Example 1.

[0034] In summary, the technical solution provided by the present invention makes up for the shortcomings of the existing technology, successfully completes the invention task, and faithfully realizes the technical effects stated by the applicant in the technical effect column above.

Claims

1. A 3D fabric structure, comprising a surface fabric (1) and a bottom fabric (2) and a middle yarn (3) for braiding and connecting the surface fabric (1) and the bottom fabric (2), wherein the surface fabric (1) is provided with a surface fabric through hole (11), and the bottom fabric (2) is provided with a bottom fabric through hole (21), the surface fabric through hole (11) and the bottom fabric through hole (21) are of the same size and correspond to each other up and down, and are respectively provided in the same state, both at intervals and continuously and repeatedly, on the surface fabric (1) and the bottom fabric (2) whose length and width are not restricted, in, The surface tissue through hole (11) has four surface tissue through hole corners (111), and the bottom tissue through hole (21) has four bottom tissue through hole corners (211), the surface tissue through hole corners (111, 211) and the bottom tissue through hole corners (111, 211) correspond to each other up and down, and the surface tissue through hole corners (111) of adjacent surface tissue through holes (11) are shared, and the bottom tissue through hole corners (211) of adjacent bottom tissue through holes (21) are also shared, and the surface tissue through hole corners (111, 211) and the bottom tissue through hole corners (111, 211) correspond to each other up and down, and are characterized in that: the middle silk (3) is woven and connected between the opposite sides of the surface tissue through hole corners (111) and the bottom tissue through hole corners (211), so that the surface tissue (1) and the bottom tissue (2) jointly form a first channel I (4), a second channel II (5), a third channel III (6), a fourth channel IV (7) and a fifth channel V (8) for ventilation.

2. A 3D fabric structure according to claim 1, Features: The number of the middle threads (3) braided and connected between the opposite sides of the surface tissue through-hole corner (111) and the bottom tissue through-hole corner (211) is four.

3. A 3D fabric structure according to claim 1, Features: The middle filaments (3) are at least partially fused and connected at the braided connection points of the surface tissue through hole corners (111) and the bottom tissue through hole corners (211).

4. A 3D fabric structure according to claim 1, Features: The surface tissue through hole (11) of the surface tissue (1) and the bottom tissue through hole (21) of the bottom tissue (2) are quadrilateral holes.

5. A 3D fabric structure according to claim 4, Features: The quadrilateral hole is a diamond hole, and the side length of the diamond hole is 0.6-1.2 mm.

6. A 3D fabric structure according to claim 1, Features: The surface fabric (1) and the bottom fabric (2) are each woven from four mixed yarns of 300D / 96F DTY yarns and 840D / 384F FDY yarns.

7. A 3D fabric structure according to claim 6, Features: The mass percentage of the 300D / 96F DTY yarn in the surface tissue (1) and the bottom tissue (2) is 60%, while the mass percentage of the 840D / 384F FDY yarn in the surface tissue (1) and the bottom tissue (2) is 40%.

8. A 3D fabric structure according to claim 6, Features: The polyester monofilament used as the middle yarn (3) is solid and has a circular cross-sectional shape.

9. A 3D fabric structure according to claim 8, Features: The diameter of the polyester monofilament used as the middle yarn (3) is 0.25-0.32 mm.

10. A 3D fabric structure according to any one of claims 1 to 9, Features: The 3D fabric composed of the surface fabric (1), the bottom fabric (2) and the middle yarn (3) woven and connected between the surface fabric (1) and the bottom fabric (2) has a gram weight of 380-520 g / m 2 .

Images