Surface material containing three-dimensional woven fabric

Abstract

This invention provides a surface material for use in seat fabrics of vehicles, furniture, and interior materials of vehicles. The surface knitted fabric is constructed using composite yarns formed from two or more different colored yarns, resulting in a superior appearance with a multicolored style. The surface material of this invention comprises a three-dimensional knitted fabric, which consists of a surface knitted fabric, an inner knitted fabric, and connecting yarns linking the surface and inner knitted fabrics. The surface knitted fabric is characterized in that at least 30% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns, and in at least 30% of the loops formed from the composite yarns, the loops formed from the composite yarns form an angle of 20 degrees or more and 80 degrees or less with adjacent loops in the transverse and / or longitudinal directions.

Description

Technical Field

[0001] This invention relates to skin materials. Background Technology

[0002] In the past, three-dimensional woven fabrics, consisting of two layers of knitted fabric and connecting yarns, have cushioning properties in the thickness direction by using monofilaments in the connecting yarns. Furthermore, by making the knitted fabrics of the two layers into a mesh structure, high breathability is ensured. As a cool and stuffy cushioning material, it is widely used in seat fabrics, bedding and other applications.

[0003] On the other hand, when using three-dimensional woven fabrics as the outer material for seat fabrics of vehicles, furniture, etc., and interior materials of vehicles, the following solution is proposed when the appearance of the surface knitted fabric of the three-dimensional woven fabric is required: by giving the surface knitted fabric a high degree of appearance by giving it a pattern based on needle selection and / or a pattern based on color yarn switching.

[0004] For example, Patent Document 1 discloses a three-dimensional transverse knitted fabric in which the transverse knitted fabrics of the outer and inner layers are connected by monofilaments, and the three-dimensional transverse knitted fabric has excellent appearance by having a pattern based on needle selection and / or a pattern based on color yarn switching on the surface of at least one side of the outer and inner knitted fabrics.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2004-107800 Summary of the Invention

[0008] The problem the invention aims to solve

[0009] However, for the knitted surface of the three-dimensional horizontal knitted fabric in Patent Document 1, the appearance of the knitted surface of the three-dimensional horizontal knitted fabric is given by the switching of the colored yarn and the switching of the pattern based on the selection of needles. However, since each loop is large, the color change is too obvious in each loop, making it difficult to give a natural variegated style appearance.

[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 problems of the prior art and to provide a surface material that, in the surface material of seat fabrics of vehicles, furniture, etc., interior materials of vehicles, etc., by weaving a composite yarn containing two or more different colored yarns into the surface knitted fabric of a three-dimensional woven fabric, and giving a certain angle to the loops formed by the composite yarn and the adjacent loops in the transverse direction and / or longitudinal direction of the loops, thereby presenting a better appearance with a natural variegated style.

[0011] Solution for solving the problem

[0012] In order to solve the above-mentioned problems, the inventors of this application conducted in-depth research and repeated experiments, and unexpectedly discovered a skin material comprising a three-dimensional knitted fabric. This three-dimensional knitted fabric is composed of an outer knitted fabric, an inner knitted fabric, and connecting yarns that connect the outer knitted fabric and the inner knitted fabric. More than 30% of the loops contained in the outer knitted fabric are formed by composite yarns containing two or more different colored yarns. In more than 30% of the loops formed by the composite yarns, the loops are arranged at an angle so that the loops formed by the composite yarns form a certain angle with the loops adjacent to each other in the transverse direction and / or longitudinal direction. This solves the above-mentioned problems and completes the present invention.

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

[0014] [1] A skin material comprising a three-dimensional knitted fabric, the three-dimensional knitted fabric being composed of an outer knitted fabric, an inner knitted fabric and a connecting yarn connecting the outer knitted fabric and the inner knitted fabric, characterized in that more than 30% of the loops contained in the outer knitted fabric are formed of a composite yarn containing two or more different colored yarns, and in more than 30% of the loops formed by the composite yarn, the loops formed by the composite yarn form an angle of more than 20 degrees and less than 80 degrees with the loops adjacent to each other in the transverse direction and / or the longitudinal direction of the loops.

[0015] [2] According to the skin material described in [1], wherein more than 50% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns.

[0016] [3] According to the skin material described in [2], wherein more than 60% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns.

[0017] [4] The skin material according to any one of [1] to [3], wherein in more than 50% of the coils formed by the composite wire, the coils formed by the composite wire form an angle of more than 20 degrees and less than 80 degrees with the coils adjacent in the transverse direction and / or longitudinal direction of the coils.

[0018] [5] The skin material according to any one of [1] to [4], wherein the three-dimensional braid has an opening of 0.3 mm or more and 2.5 mm or less, and more than 30% of the coils formed by the composite yarn face the opening of 0.3 mm or more and 2.5 mm or less.

[0019] [6] According to the skin material described in [5], more than 50% of the coils formed from the composite filament face the opening of 0.3 mm or more and 2.5 mm or less.

[0020] [7] According to the outer material of [5] or [6], wherein the inner knitted fabric comprises a filament whose color is darker than at least one of the composite filaments of the outer knitted fabric.

[0021] [8] The skin material according to any one of [1] to [7], wherein more than 30% of the coils formed by the composite filaments are adjacent to coils formed by filaments of a different color than at least one of the composite filaments in the transverse and / or longitudinal directions of the coils.

[0022] [9] The skin material according to any one of [1] to [8], wherein, in the surface knitted fabric, the fineness of the composite yarn is 150 dtex or more and 800 dtex or less.

[0023]

[10] The outer skin material according to any one of [1] to [9], wherein the knitting density of the outer knitted fabric is more than 20 loop rows / 2.54 cm and less than 43 loop rows / 2.54 cm, and is more than 18 loop rows / 2.54 cm and less than 34 loop rows / 2.54 cm.

[0024] The effects of the invention

[0025] For the surface material of the present invention containing three-dimensional woven fabric, by weaving a composite yarn containing two or more different colored yarns into the surface knitted fabric of the three-dimensional woven fabric, and giving a certain angle to the loops formed by the composite yarn and the loops adjacent to each other in the transverse direction and / or longitudinal direction of the loops, a natural variegated appearance is presented. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of an example of this embodiment where the loops formed by composite yarns in the surface knitted fabric form an angle with the loops adjacent to each other in the transverse direction of the loops.

[0027] Figure 2 This is a schematic diagram of an example of this embodiment where the loops formed by composite yarns in the surface knitted fabric form an angle with the loops adjacent to each other in the longitudinal direction of the loops.

[0028] Figure 3 This is a schematic diagram of an example of this embodiment, showing the loops of the surface knitted fabric formed from composite yarns facing the opening. Detailed Implementation

[0029] The embodiments of the present invention will be described in detail below.

[0030] An embodiment of the present invention (also referred to as this embodiment) provides a skin material comprising a three-dimensional knitted fabric, which is composed of a surface knitted fabric, an inner knitted fabric, and a connecting yarn connecting the surface knitted fabric and the inner knitted fabric. The surface knitted fabric contains at least 30% of its loops formed from composite yarns comprising two or more different colored yarns. In at least 30% of the loops formed from the composite yarns, the loops formed from the composite yarns form an angle of 20 degrees or more and 80 degrees or less with adjacent loops in the transverse and / or longitudinal directions of the loops.

[0031] The outer material of this embodiment comprises a three-dimensional woven fabric, which consists of an outer knitted fabric, an inner knitted fabric, and connecting yarns that link the two knitted fabrics together. The three-dimensional woven fabric is knitted using a double-sided Raschel warp knitting machine or a double-sided circular knitting machine, preferably using a machine size of 18 to 32.

[0032] In the three-dimensional woven fabric constituting the outer skin material of this embodiment, more than 30% of the loops in the outer knitted fabric are formed from composite yarns containing two or more different colored yarns. In this embodiment, composite yarns containing two or more different colored yarns refer to yarns formed by combining two or more yarns with different color-related properties such as hue, chroma, brightness, and luster through processes such as twisting, interlacing, air-jet processing, and compound false twisting. The two or more different colored yarns refer to pre-dyed yarns such as solution-dyed yarns and pre-spinning dyed yarns, but can also be yarns that have been dyed after the greige fabric of the three-dimensional woven fabric is woven. To suppress quantitative changes in the three-dimensional woven fabric based on dyeing processing, the two or more different colored yarns are more preferably solution-dyed yarns and pre-spinning dyed yarns, and even more preferably solution-dyed yarns that do not require a dyeing process. Furthermore, the colored yarns include undyed white yarns.

[0033] The statement that more than 30% of the loops in a surface knitted fabric are formed by a composite yarn containing two or more different colored yarns means that more than 30% of all loops in a certain area of ​​the surface knitted fabric are formed by this composite yarn. The proportion of loops formed by this composite yarn is calculated as follows: Observing any part of the surface knitted fabric from the surface side, calculate the ratio of the number of loops formed by this composite yarn in a certain area (for example, 1 cm square) to the total number of loops.

[0034] By forming more than 30% of the loops in the surface knitted fabric from a composite yarn containing two or more different colored filaments, the surface knitted fabric becomes an appearance of a natural variegated style. The proportion of the loops formed from the composite yarn is more preferably 50% or more, and further preferably 60% or more.

[0035] For the three-dimensional knitted fabric constituting the skin material of the present embodiment, in more than 30% of the loops in the surface knitted fabric formed from a composite yarn containing two or more different colored filaments, the loops formed from the composite yarn form an angle of 20 degrees or more and 80 degrees or less with the adjacent loops in the loop row direction and / or the loop column direction. The proportion of the loops is more preferably 50% or more, and further preferably 60% or more.

[0036] In addition, the proportion of the loops formed from a composite yarn containing two or more different colored filaments that form an angle is calculated by the following method: At an arbitrary part of the surface knitted fabric, when observed from the front side, the proportion of the number of loops of the composite yarn that form an angle of 20 degrees or more and 80 degrees or less with the adjacent loops in a certain area (for example, a 1 cm square) with respect to the total number of loops of the composite yarn is calculated.

[0037] If more than 30% of the loops formed from a composite yarn containing two or more different colored filaments form an angle of 20 degrees or more and 80 degrees or less, the loops formed from the composite yarn will not be arranged too linearly in the loop row direction and / or the loop column direction. While showing a more natural variegated style, it becomes a variegated pattern in a snowflake style (Japanese: shimoori-chou) where the colors are distributed in a substantially inclined direction, and the appearance is further improved, which is thus preferable. The angle is more preferably 30 degrees or more and 70 degrees or less.

[0038] Regarding the angle formed by the loops formed from a composite yarn containing two or more different colored filaments and the adjacent loops, a schematic view of the state where the loops formed from a composite yarn containing two or more different colored filaments form an angle of X degrees with the adjacent loops in the loop row direction (horizontal direction) is shown in Figure 1 In, a schematic view of the state where the loops formed from a composite yarn containing two or more different colored filaments form an angle of Y degrees with the adjacent loops in the loop column direction (vertical direction) is shown in Figure 2 In.

[0039] In Figure 1In the process of observing the knitted fabric from the surface side with the knitting start direction set to the bottom, a straight line L1 is drawn from the lowest point (a) of the loop (4) on the left and right sides of the loop (4) formed by two loops (4, 5) of a loop 1 made of composite yarn containing two or more different colored yarns, connecting the highest point (b) of the loop (4) to the lowest point (a) of the loop (4) that is visible. Similarly, in the loop (7) on the left and right sides of the loop (6, 7) of the loop 2 adjacent to the loop 1 in the horizontal direction of the loop, a straight line L2 is drawn from the lowest point (c) of the loop (7) to the highest point (d) of the loop (7) that is visible. The angle of the open portion formed by the intersection of the obtained straight lines L1 and L2 in the knitting end direction is set as X degrees.

[0040] In addition, Figure 2 In the longitudinal direction of the coil and the coil 3 adjacent to a coil 1 formed by a composite yarn containing two or more different colored yarns, the two loops (8, 9) on the left and right sides of the coil 3, which are composed of fiber bundles, include the loop (9) on one side located on the outermost surface side. The lowest point (e) of the loop (9) that can be seen is connected to the highest point (f) of the loop (9) that can be seen by using a straight line L3. The angle of the open part in the weaving end direction formed by the intersection of the obtained straight lines L1 and L3 is set as Y degrees.

[0041] A loop adjacent to a loop formed by a composite yarn containing two or more different colored yarns can be either the same composite yarn or a different colored yarn. When the adjacent loop is formed by a yarn that is different from at least one of the colored yarns in the composite yarn, it will become a more natural variegated style or a variegated style containing geometric patterns, depending on the knitting structure, which is preferred.

[0042] In the three-dimensional knitted fabric constituting the outer skin material of this embodiment, in order to make the appearance of the surface knitted fabric more three-dimensional and multicolored, it is preferable that at least 30% of the loops formed by the composite yarn containing two or more different colored yarns in the surface knitted fabric have an opening of 0.3 mm or more and 2.5 mm or less. In this embodiment, an opening refers to a gap formed in a row of loops connected in the longitudinal direction of the surface knitted fabric, such that adjacent loop rows are separated by a gap of 0.3 mm or more in the transverse direction of the loop row. Even if the knitting pattern yarn is inserted in a way that fills this gap, this gap is considered an opening. The proportion of loops formed by the composite yarn containing two or more different colored yarns facing the opening of 0.3 mm or more and 2.5 mm or less is more preferably 40% or more, and even more preferably 50% or more. In addition, the proportion of loops facing the opening is calculated as follows: at any part of the surface knitted fabric, from the surface side, the proportion of the number of loops of composite yarn containing two or more different colored yarns facing the opening of 0.3mm or more and 2.5mm or less in a certain area (for example, 1cm square) is calculated relative to the total number of loops of composite yarn containing two or more different colored yarns.

[0043] exist Figure 3 The diagram shows an opening 10 (with opening size K in mm) and an opening 11 (with opening size S in mm) facing a coil 1 formed from a composite filament containing two or more different colored filaments. The opening refers to the opening on the left and right outer sides of the two coil posts (4, 5) facing the coil 1. The opening size represents the length of the opening connected by a straight line along the horizontal line in the transverse direction of the coil, connecting the two points with the longest straight-line distance.

[0044] When the loops of the composite yarn containing two or more different colored yarns in the outer knitted fabric face the opening, if a colored yarn such as black, which is darker than at least one of the colored yarns in the composite yarn of the outer knitted fabric, is used in the inner knitted fabric to make the appearance more three-dimensional, the color pattern of the composite yarn will be visible because the dark color of the inner knitted fabric seen through the opening will make the color pattern of the composite yarn visible.

[0045] In the surface knitted fabric of a three-dimensional knitted fabric, as a method for creating an opening in a manner that faces the loop formed by composite yarns containing two or more different colored yarns, it is preferable to use a method in which any part of the surface knitted fabric is set as a mesh or rib structure, and the composite yarns are arranged at the opening position of the mesh or rib structure.

[0046] To create a mesh or rib knit fabric, any warp knitting structure can be used. In the case of a mesh structure, it is preferable to form a mesh structure with a 1-in-1-out or 2-in-2-out needle-dropping arrangement when at least two reeds are used on a knitting machine and the yarn is fed from the guide rods. In the case of a rib knit fabric, a preferred method is to use a 1-in-1-out or 2-in-2-out needle-dropping arrangement when at least two reeds are used on a knitting machine and the yarn is fed from the guide rods, and to appropriately pull the sinker arcs of at least two or more rows of loops connected in the longitudinal direction of the knit fabric supplied by the two guide rods in opposite directions, thereby bringing the loops closer together to form a convex rib structure.

[0047] For mesh or rib knitting, it is not necessary for all the loop rows of the knitted fabric to be the same mesh or rib knitting. Instead, a combination of different knitting structures can be used in a portion of the loop rows.

[0048] If a patterned yarn, which differs in appearance (color, shape, luster, etc.) from at least one of the composite yarns containing two or more different colored yarns forming the surface knitted fabric, is inserted and knitted across the opening at any angle along a generally longitudinal, generally transverse, or generally oblique direction when viewed from the surface of the surface knitted fabric, it will present a more profound appearance, which is preferred.

[0049] In the surface knitted fabric of the three-dimensional knitted fabric of this embodiment, in order to achieve a more natural variegated appearance and to suppress the pulling out and pilling of single fibers of the composite yarn containing two or more different colored yarns when the surface knitted fabric is rubbed by hard protrusions such as the hooks of hook-and-loop fasteners, the fineness of the composite yarn, i.e., the total fineness of the two or more different colored yarns, is preferably 150 dtex or more and 800 dtex or less. Furthermore, the fineness of the single filament of the composite yarn is preferably 1 dtex or more and 6 dtex or less, more preferably 3 dtex or more and 6 dtex or less to increase the strength of the single filament.

[0050] From the viewpoint of imparting a natural variegated feel and suppressing the pulling out and pilling of single fibers in the composite yarn, the knitting density of the surface knitted fabric is preferably 20 loop rows / 2.54cm or more and 43 loop rows / 2.54cm or less, and 18 loop warp rows / 2.54cm or more and 34 loop warp rows / 2.54cm or less. More preferably, the total fineness of the composite yarn is 200 dtex or more and 500 dtex or less, and the knitting density is 25 loop rows / 2.54cm or more and 43 loop rows / 2.54cm or less, and 20 loop warp rows / 2.54cm or more and 30 loop warp rows / 2.54cm or less.

[0051] From the same perspective, the total fineness of a single loop in the surface knitted fabric is preferably 150 dtex or more and 800 dtex or less. Furthermore, a loop formed from a composite yarn containing two or more different colored yarns does not necessarily have to be formed from a single composite yarn; it can also be formed by combining it with other yarns.

[0052] In this embodiment, the fiber used in the connecting yarn of the three-dimensional braided fabric is preferably a monofilament. When a monofilament is used as the connecting yarn, in order to suppress the protrusion of the monofilament relative to the surface of the knitted fabric and maintain good cushioning, its fineness is preferably 30 dtex or more and 300 dtex or less, more preferably 50 dtex or more and 250 dtex or less.

[0053] 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 knit into the loops of the monofilament in a manner in which the monofilament does not protrude from the surface of the surface knit. For this purpose, the fineness D2 (dentex) of the monofilament preferably satisfies the following relationship with respect to the total fineness D (dentex) of a loop formed by the fibers forming the surface knit.

[0054] D / D2≥3.

[0055] In the three-dimensional knitted fabric of this embodiment, any fiber can be used for the outer knitted fabric, the inner knitted fabric, and the connecting yarn. However, considering the strength and light resistance of the raw yarn, it is preferable to use long fibers of polyethylene terephthalate fiber for the outer knitted fabric and the inner knitted fabric.

[0056] The use of 100% polyethylene terephthalate fibers for the outer knitted fabric, inner knitted fabric, and connecting yarn is preferred when considering ease of recycling, such as material recycling and chemical recycling. These fibers can be undyed, and solution-dyed or pre-spinning-dyed yarns are preferred to suppress quantitative changes in the three-dimensional knitted fabric during dyeing processes. Furthermore, solution-dyed yarns incorporating pigments or the like are more preferred, as they do not require a dyeing process.

[0057] The thickness of the three-dimensional woven fabric in this embodiment can be set arbitrarily. From the viewpoint of sewing and processing properties as a surface material, it is preferably 2.5 mm or more and 12 mm or less, and more preferably 3 mm or more and 8 mm or less.

[0058] The weight per unit area of ​​the three-dimensional woven fabric constituting the skin material in this embodiment can be set arbitrarily, but is preferably 300 to 1000 g / m². 2 More preferably 400–900 g / m 2 .

[0059] Regarding the finishing method for the three-dimensional woven fabric of this embodiment, when using 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 solely through heat setting. When any one of the fibers used in the outer knitted fabric, inner knitted fabric, or connecting yarn is an undyed three-dimensional woven fabric, the greige fabric can be finished through processes such as pre-setting, scouring, dyeing, and heat setting.

[0060] When the surface material of this embodiment is used in seat fabrics, automotive interior materials, etc., polyurethane can be laminated on the back as with conventional surface materials. However, it is preferable to use it without lamination from the perspective of recyclability.

[0061] Example

[0062] 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.

[0063] The methods for measuring various physical properties of the three-dimensional woven fabrics used in the following examples are as follows.

[0064] (a) The angle (in degrees) between a coil formed by a composite filament containing two or more different colored filaments and an adjacent coil.

[0065] Using a ONESHOT 3D measuring microscope VR-3000 manufactured by KEYENCE CORPORATION, the surface of the three-dimensional knitted fabric was photographed at any position on the outer surface of the surface layer, with the knitting start direction as the near-front side (bottom of the image) and autofocused at 40x magnification. In the captured 3D image, a straight line was drawn connecting the lowest visible point of the loop (the bottom of the image) to the highest visible point (the top of the image) within the loop formed by two fiber bundles on either side of a loop consisting of composite yarns containing two or more different colors. Furthermore, when the height of the outermost surface of both loops is the same, the loop with the larger angle to the adjacent loop was selected. Furthermore, in the coils adjacent to the coil containing composite yarns of two or more different colors in both the transverse and longitudinal directions, a straight line is drawn connecting the lowest point of the visible coil (the bottommost point in the image) to the highest point of the visible coil (the topmost point in the image) in the single-sided coil containing the portion located closer to the outermost surface of the two coil pillars formed by fiber bundles. The angle of the open portion formed by the intersection of the two obtained straight lines in the weaving end direction is measured. During the measurement, all coils formed by composite yarns containing two or more different colors within a certain area (0.7 cm square to 1 cm square) of the 3D image are measured in both the transverse and longitudinal directions.

[0066] (b) Opening size (mm)

[0067] Based on the 3D image captured by (a), the opening size is obtained by measuring the length of the longest straight-line distance between two points on the horizontal line in the transverse direction (lateral direction) of the coil facing the opening of the coil composed of a composite filament containing two or more different colored filaments.

[0068] (c) Fineness (denier) of composite yarn

[0069] Unravel the outer knit of the three-dimensional knitted fabric, pull out composite yarns longer than 10 cm, and measure the length and weight of a single composite yarn under a load of 15 gf, then calculate the fineness. Pull out three composite yarns and calculate the average value. If the fineness can be measured before knitting the three-dimensional knitted fabric, measure it according to JIS L 1013.

[0070] (d) The appearance of the variegated style

[0071] Visually inspect the surface knit of the three-dimensional woven fabric from the side, and determine its appearance (whether it has a mottled or mixed-color style) using the following grading system. Each grade is 0.5.

[0072] Level 5: Shows a very natural variegated style.

[0073] Level 4: Shows a fairly natural variegated style.

[0074] Level 3: Shows a slightly natural variegated style.

[0075] Level 2: Almost no natural variegated style is visible.

[0076] Level 1: No natural variegated style shown at all

[0077] (e) A three-dimensional, variegated aesthetic

[0078] Visually inspect the surface knit of the three-dimensional woven fabric from the side, and determine its depth and three-dimensionality within the multicolored pattern using the following rating system. Ratings are given in increments of 0.5.

[0079] Level 5: Extremely deep

[0080] Level 4: Has a considerable sense of depth

[0081] Level 3: Slightly has a sense of depth

[0082] Level 2: Almost no sense of depth

[0083] Level 1: Absolutely no sense of depth

[0084] (f) The variegated appearance of the slanted snowflakes

[0085] Visually inspect the surface knit of the three-dimensional woven fabric from the side, and determine the following grading based on whether the multicolored pattern is distributed along a diagonal direction. Grading is done in increments of 0.5.

[0086] Level 5: Extremely shows a variegated style distributed along the slant direction.

[0087] Level 4: Equivalent to a variegated style distributed along a diagonal direction.

[0088] Level 3: Slightly shows a variegated style distributed along the diagonal direction.

[0089] Level 2: Almost no variegated style distributed along the diagonal direction is shown.

[0090] Level 1: No noise style distributed along the diagonal direction is shown.

[0091] [Example 1]

[0092] Using a size 22 double-sided Raschel knitting machine equipped with 6 reeds and a needle barrel spacing of 6mm, two false-twist processed yarns of 167 dtex 48 filament polyethylene terephthalate fiber (black solution-dyed yarn) and 167 dtex 48 filament polyethylene terephthalate fiber (white yarn) are twisted together from the two reeds (L1, L2) forming the surface knitted fabric. The twists are 120 twists / m to form a composite yarn. The yarn is supplied in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement. 110 dtex polyethylene terephthalate fiber (black solution dyed yarn) monofilament is supplied from one reed (L3) forming the connecting part in a 1-in-1-out arrangement. Then, 167 dtex polyethylene terephthalate fiber (black solution dyed yarn) false twist processing yarn with 48 filaments is supplied from two reeds (L4, L5) forming the inner knitted fabric in a full-in arrangement.

[0093] Using the knitting structure shown below, with the machine loops set to 35 loop rows / 2.54cm, a greige fabric for a three-dimensional woven fabric is woven. The resulting greige fabric is then subjected to dry heat setting for 1 minute at 175°C with 0% stretching and 0% overfeed to obtain a three-dimensional woven fabric with the various physical properties shown in Table 1 below, which is used as the outer skin material.

[0094] (Knitted structure)

[0095] L1: 1011 / 2322 / (1 in, 1 out)

[0096] L2: 2322 / 1011 / (1 out, 1 in)

[0097] L3: 3410 / 4367 / (1 in, 1 out)

[0098] L4: 1110 / 0001 / (All In)

[0099] L5: 2210 / 2234 / (All In)

[0100] [Example 2]

[0101] Except for the knitting structure shown below, a greige fabric for a three-dimensional woven fabric is woven in the same manner as in Example 1. The obtained greige fabric is heat-set in the same manner as in Example 1 to obtain a three-dimensional woven fabric having the various physical properties shown in Table 1 below, which is used as the skin material.

[0102] (Knitted structure)

[0103] L1: 1011 / 1233 / 4544 / 4322 / (1 in, 1 out)

[0104] L2: 4544 / 4322 / 1011 / 1233 / (1 out, 1 in)

[0105] L3: 3410 / 3245 / 2145 / 2310 / (1 in, 1 out)

[0106] L4: 1110 / 0001 / (All In)

[0107] L5: 2210 / 2234 / (All In)

[0108] [Example 3]

[0109] Except for the knitting structure shown below, a greige fabric for a three-dimensional woven fabric is woven in the same manner as in Example 1. The obtained greige fabric is heat-set in the same manner as in Example 1 to obtain a three-dimensional woven fabric having the various physical properties shown in Table 1 below, which is used as the skin material.

[0110] (Knitted structure)

[0111] L1: (1011 / 2322 / )×3(1011 / 1211 / )×3(1 in, 1 out)

[0112] L2: (2322 / 1011 / )×3(3233 / 3433 / )×3(1 out, 1 in)

[0113] L3: (3410 / 4367 / )×3(4367 / 3410 / )×3(1 in, 1 out)

[0114] L4: 1110 / 0001 / (All In)

[0115] L5: 2210 / 2234 / (All In)

[0116] [Example 4]

[0117] Except for the knitting structure shown below, a greige fabric for a three-dimensional woven fabric is woven in the same manner as in Example 1. The obtained greige fabric is heat-set in the same manner as in Example 1 to obtain a three-dimensional woven fabric having the various physical properties shown in Table 1 below, which is used as the skin material.

[0118] (Knitted structure)

[0119] L1: 1011 / 1211 / (1 in, 1 out)

[0120] L2: 1011 / 1211 / (1 out, 1 in)

[0121] L3: 4367 / 3410 / (1 in, 1 out)

[0122] L4: 0001 / 1110 / (All In)

[0123] L5: 2234 / 2210 / (All In)

[0124] [Examples 5 to 7]

[0125] Using a size 22 double-sided Raschel knitting machine equipped with 6 reeds and a needle barrel spacing of 6mm, two false-twist processed yarns of 167 dtex 48 filament polyethylene terephthalate fiber (black solution-dyed yarn) and 167 dtex 48 filament polyethylene terephthalate fiber (white yarn) are twisted together from the two reeds (L1, L2) forming the surface knitted fabric. These yarns are twisted at a twist rate of 120 twists / m to form a composite yarn, and a 334 dtex 72 filament polyethylene terephthalate fiber is also twisted. The false-twisted processed yarns of black solution-dyed yarn were supplied in the following order: two composite yarns and one 334 / 72 false-twisted processed yarn (Example 5); one composite yarn and one 334 / 72 false-twisted processed yarn (Example 6); and one composite yarn and two 334 / 72 false-twisted processed yarns (Example 7). These were supplied relative to the yarn guide in a 1-in-1-out (L1) and 1-out-1-in (L2) arrangement. Otherwise, similar to Example 1, the fabrics were woven into three-dimensional woven fabrics with different composite yarn mixing ratios. The resulting fabrics were subjected to dry heat setting, similar to Example 1, to obtain three-dimensional woven fabrics with the various physical properties shown in Tables 1 and 2 below, which were used as the outer skin material.

[0126] [Comparative Example 1]

[0127] From one reed (L1) forming the surface knitted fabric, false-twisted polyethylene terephthalate (PET) fibers (black solution-dyed yarn) of 334 dpi 72 filaments are supplied in a 1-in-1-out arrangement. From another reed (L2), false-twisted PET fibers (white yarn) of 334 dpi 72 filaments are supplied in a 1-out-1-in arrangement. Otherwise, the fabric for the three-dimensional knitted fabric is woven in the same manner as in Example 1. The resulting fabric is heat-set in the same manner as in Example 1 to obtain a three-dimensional knitted fabric having the various physical properties shown in Table 2 below, which is used as the outer skin material.

[0128] [Comparative Example 2]

[0129] Using a double-sided Raschel knitting machine equipped with 6 reeds and a gauge of 18, with a needle barrel spacing of 6mm, the two reeds (L1, L2) forming the outer knit fabric are supplied with a composite yarn made of 167 dtex polyethylene terephthalate fiber (black solution dyed yarn) with 48 filaments and 167 dtex polyethylene terephthalate fiber (white yarn) with 48 filaments interlaced together, both in a full-feed arrangement. From the reed (L3) forming the connecting part, a single filament of 200 dtex polyethylene terephthalate fiber (black solution dyed yarn) is supplied in a 1-in-1-out arrangement. Then, from the two reeds (L4, L5) forming the inner knit fabric, a false-twist yarn of 167 dtex polyethylene terephthalate fiber (black solution dyed yarn) with 48 filaments is supplied in a full-feed arrangement.

[0130] Using the knitting structure shown below, with the machine loop rows set to 16 loop rows / 2.54cm, a greige fabric for a three-dimensional woven fabric is woven. The resulting greige fabric is heat-set in the same manner as in Example 1 to obtain a three-dimensional woven fabric with the various properties shown in Table 2 below, which is used as the outer skin material.

[0131] (Knitted structure)

[0132] L1: 1011 / 2322 / (All In)

[0133] L2: 2322 / 1011 / (All In)

[0134] L3: 3410 / 4367 / (1 in, 1 out)

[0135] L4: 1110 / 0001 / (All In)

[0136] L5: 2210 / 2234 / (All In)

[0137] [Table 1]

[0138]

[0139] [Table 2]

[0140]

[0141] As shown in Tables 1 and 2, for the outer skin material formed by the three-dimensional knitted fabric of Examples 1 to 7, in which more than 30% of the loops in the outer knitted fabric contain composite yarns of two different colors, it exhibits a better appearance with a natural variegated style compared to Comparative Example 1, in which the outer knitted fabric does not contain composite yarns of two different colors and has loops of different colors formed by two different colors supplied from different reeds arranged alternately, and Comparative Example 2, in which the proportion of loops formed by composite yarns of two different colors with an angle of 20 degrees or more and 80 degrees or less between adjacent loops is less than 30%.

[0142] In comparing the ratio of two different colored yarns in the loops of the surface knitted fabric, Examples 1, 5, 6, and 7 were compared. The higher the mixing ratio, the better the appearance of the natural variegated style.

[0143] Furthermore, when comparing Examples 1, 2, and 3, which differ in the proportion of coils formed by composite wires of two different colored wires to coils of composite wires with an angle of 20 degrees or more and 80 degrees or less between adjacent coils, the higher the proportion, the more it exhibits the appearance of a variegated style resembling oblique snowflakes.

[0144] When comparing Examples 1, 2, and 3, which use composite filaments of two different colors with different coil proportions facing an opening size of 0.3mm or more and 2.5mm or less, the higher the proportion of coils facing the opening, the more pronounced the three-dimensional, variegated appearance is.

[0145] Industrial availability

[0146] The skin material of the present invention can be used on cushioning components such as polyurethane padding of seat fabrics in vehicles, furniture, etc., or as a skin material for interior materials such as seat fabrics, vehicle roofs, and door interior panels formed by being stretched on a fabric frame. It is suitable as a skin material with good appearance by using composite yarns formed from two or more different colored yarns to form a surface knitted fabric, thus presenting an appearance with a multicolored style.

[0147] Explanation of reference numerals in the attached figures

[0148] 1. A coil formed from composite yarns containing two or more different colored yarns; 2. Adjacent coils in the transverse direction; 3. Adjacent coils in the longitudinal direction; 4. A coil column composed of fiber bundles; 5. A coil column composed of fiber bundles; 6. A coil column composed of fiber bundles; 7. A coil column composed of fiber bundles; 8. A coil column composed of fiber bundles; 9. A coil column composed of fiber bundles; 10. An opening; 11. An opening; L1. A straight line connecting the lowest and highest points of the visible coil column; L2. A straight line connecting the lowest and highest points of the visible coil column. L3, a straight line connecting the lowest and highest points of the visible coil; K, opening size; S, opening size; X, the angle between a coil formed by a composite filament containing two or more different colored filaments and an adjacent coil; Y, the angle between a coil formed by a composite filament containing two or more different colored filaments and an adjacent coil; a, the lowest point of the visible coil; b, the highest point of the visible coil; c, the lowest point of the visible coil; d, the highest point of the visible coil; e, the lowest point of the visible coil; f, the highest point of the visible coil.

Claims

1. A skin material comprising a three-dimensional woven fabric, the three-dimensional woven fabric being composed of a surface knitted fabric, an inner knitted fabric, and connecting yarns linking the surface knitted fabric and the inner knitted fabric, characterized in that, More than 30% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns. In more than 30% of the loops formed from the composite yarns, the acute angle formed by the loops formed from the composite yarns and the adjacent loops in the transverse and / or longitudinal directions of the loops is more than 20 degrees and less than 80 degrees.

2. The skin material according to claim 1, wherein, More than 50% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns.

3. The skin material according to claim 2, wherein, More than 60% of the loops in the surface knitted fabric are formed from composite yarns containing two or more different colored yarns.

4. The skin material according to any one of claims 1 to 3, wherein, In more than 50% of the coils formed by the composite wire, the coils formed by the composite wire form an angle of more than 20 degrees and less than 80 degrees with the coils adjacent in the transverse and / or longitudinal directions of the coils.

5. The skin material according to any one of claims 1 to 3, wherein, The three-dimensional braided fabric has an opening of 0.3 mm or more and 2.5 mm or less, and more than 30% of the coils formed from the composite yarn face the opening of 0.3 mm or more and 2.5 mm or less.

6. The skin material according to claim 5, wherein, More than 50% of the coils formed from the composite wire face the opening of 0.3 mm or more and 2.5 mm or less.

7. The skin material according to claim 5, wherein, The inner knitted fabric contains yarns whose color is darker than at least one of the colored yarns in the composite yarns of the outer knitted fabric.

8. The skin material according to any one of claims 1 to 3, wherein, More than 30% of the coils formed from the composite filament are adjacent to coils formed from filaments of a different color than at least one of the filaments in the composite filament in the transverse and / or longitudinal directions of the coils.

9. The skin material according to any one of claims 1 to 3, wherein, In the surface knitted fabric, the fineness of the composite yarn is above 150 dtex and below 800 dtex.

10. The skin material according to any one of claims 1 to 3, wherein, The knitting density of the surface knitted fabric is more than 20 loop rows / 2.54cm and less than 43 loop rows / 2.54cm, and more than 18 loop warp rows / 2.54cm and less than 34 loop warp rows / 2.54cm.

11. The skin material according to claim 1, wherein, The fiber used in the connecting wire is a monofilament with a fineness of 30 dtex or more and 300 dtex or less.

12. The skin material according to claim 11, wherein, The loops of the fibers forming the surface knitted fabric are pressed into the loops of the monofilament in such a way that the monofilament does not protrude from the surface of the surface knitted fabric.

13. The skin material according to claim 11 or 12, wherein, The fineness D2 of the monofilament, relative to the total fineness D of a loop formed by the fibers constituting the surface knitted fabric, satisfies the following relationship: D / D2≥3, where the total fineness D and the fineness D2 are in deciter units.

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