Three-dimensional fabric unit
By designing three-dimensional fabric units and using environmentally friendly fibers and specific yarn processes to form a unique structure, the environmental protection and functionality issues of traditional automotive interior materials are solved, improving the comfort and performance of automotive interiors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-02
- Publication Date
- 2026-03-24
Smart Images
Figure CN121719010A_ABST
Abstract
Description
Technical Field
[0001] This application relates to a three-dimensional fabric, and more particularly to a three-dimensional fabric unit for automotive wrapping composite interior parts. Background Technology
[0002] Automobiles, especially family cars, have become integrated vehicles with multiple functions, and consumers have increasingly strong demands for personalized, functional, and diversified car interiors. Fabrics, due to their wear resistance, durability, strong anti-aging properties, good breathability, and stable chemical properties, as well as their ability to be flexibly designed and developed through various methods, are widely used in automotive interior components.
[0003] With the development of technology, new textile technologies are constantly emerging. For example, the three-dimensional integrated molding process of flat knitting technology makes it possible to weave and wrap automotive interior leather materials. Warp-knitted spacer fabric composite fabric developed by double needle bed warp knitting technology can replace polyurethane foam and has a variety of excellent properties such as resilience and compression resistance.
[0004] Furthermore, users are increasingly concerned about environmental protection and health. Traditional automotive interior composite materials, such as polyurethane foam, contain irritating odors and volatile harmful substances, while new materials such as 3D cotton are more environmentally friendly in their production process, creating a healthier driving environment in the car. For example, 3D cotton, made from recycled materials such as mineral water bottles, clothing scraps, and discarded fishing nets, saves resources and reduces pollution.
[0005] Three-dimensional fabric is a new type of environmentally friendly woven three-dimensional material with a sponge-like three-dimensional structure, such as a vertical fiber web structure or a honeycomb fiber web structure, which differs from the parallel fiber web structure of traditional nonwoven materials. It boasts numerous advantages, including recyclability, resistance to decomposition and yellowing, non-toxicity, strong flame retardancy, high resilience, high compressive strength, lightweight feel, high breathability, and easy cleaning. It is highly suitable for automotive upholstery components, enhancing the quality and comfort of automotive interiors.
[0006] The development from traditional two-dimensional planar fabrics to three-dimensional fabrics involves the addition of a longitudinal warp system, with yarns interwoven and distributed in three-dimensional space. As a type of three-dimensional fabric, three-dimensional spacer fabric typically consists of two independent surface layers and an intermediate spacer layer, forming a unique sandwich structure.
[0007] Three-dimensional spacer fabrics possess numerous superior properties. Their unique structure allows for the retention of a large amount of still air within the spacer layers, resulting in excellent thermal insulation. Simultaneously, they are lightweight, exhibit excellent moisture absorption and breathability, are compression resistant, possess high strength, and have good resilience, providing users with a comfortable experience. They can be widely used in clothing, furniture, sporting goods, and other fields.
[0008] Furthermore, in other civilian sectors, people are increasingly demanding higher performance from textiles. For example, in the clothing industry, consumers expect garments to not only be aesthetically pleasing but also possess excellent breathability, warmth, and comfort. Three-dimensional interlocking fabrics can also be used to create functional clothing to meet these needs.
[0009] In the furniture industry, three-dimensional spacer fabrics can be used in the production of mattresses and cushions, providing excellent breathability and elasticity. In the sporting goods sector, three-dimensional spacer fabrics can be used to make uppers and insoles for high-end athletic shoes, enhancing breathability and providing cushioning protection. Summary of the Invention
[0010] To address the above technical problems, this application provides a three-dimensional fabric unit, wherein the three-dimensional fabric unit includes:
[0011] Intermediate layer, wherein the intermediate layer is a single coil or a single coil in the horizontal and vertical rows, the spacer wire specification is a single bundle or a single strand, the thickness is 10dtex-300dtex: single strand or number of strands is 1-90: the yarn specification is a single bundle or number of strands, the breaking strength is ≤7cN / dtex;
[0012] The upper and lower layers are formed by weaving on the upper and lower sides of the intermediate layer, wherein the yarn of the upper and lower layers is a single bundle or a single strand with a f number, and its specification is selected as 20dtex-300dtex; wherein the single bundle or f number of the yarn is 1f-600f; the thickness of the single bundle or f number of the yarn is 0.03dtex-300dtex; and the breaking strength of the single bundle or f number of the yarn is ≤5cN / dtex.
[0013] According to one embodiment of this application, the intermediate layer, the upper layer, and the lower layer are manufactured using yarn processes including at least one of FDY fully drawn yarn, DTY drawn textured yarn, BCF bulked continuous filament, and HOY highly oriented yarn.
[0014] According to one embodiment of this application, the yarn is made of fiber raw material, wherein the fiber raw material is selected from at least one of: polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber or polyvinyl alcohol formal fiber.
[0015] According to one embodiment of this application, the coil density of the upper layer and the lower layer is implemented as follows: 6-12 coils per centimeter of horizontal row and 10-30 coils per centimeter of vertical row.
[0016] According to one embodiment of this application, the density of the interlayer fabric spacer yarn is: 120 to 64,800 single yarns per square centimeter.
[0017] According to one embodiment of this application, the thickness of the three-dimensional fabric is 1.2mm-20mm.
[0018] According to one embodiment of this application, the surface layer is formed by the following manner: knitting of the front and rear needle beds in warp knitting, where the guide needle moves 0-2 needles horizontally once or continuously before the discarding needle hook, including both unidirectional and counter-directional yarn padding knitting, and both open and closed yarn padding knitting. The guide needle moves 0-4 needles horizontally once or continuously behind the discarding needle hook, including both unidirectional and counter-directional yarn padding knitting, and both open and closed yarn padding knitting.
[0019] According to one embodiment of this application, the intermediate layer is formed in the following manner: During warp knitting of the front and rear needle beds, the guide needle moves 0-2 needles horizontally once or continuously before the discarding needle hook, including both unidirectional and counter-directional yarn padding knitting, and both open and closed yarn padding knitting. During the front and rear needle beds knitting, the guide needle moves 0-6 needles horizontally once or continuously behind the discarding needle hook, including both unidirectional and counter-directional yarn padding knitting, and both open and closed yarn padding knitting.
[0020] According to one embodiment of this application, the yarn threading method of the upper layer, the lower layer, and the middle layer is: threading the yarn through the yarn guide needle hole to fully thread or threading one part and leaving one part empty. Attached Figure Description
[0021] Figure 1 A three-dimensional view of a three-dimensional fabric unit is shown.
[0022] Figure 2 The attached diagram shows the number of individual yarns or the number of yarn combinations.
[0023] Figure 3 The attached diagram shows the coil density (both horizontal and vertical) and the number of coils. Detailed Implementation
[0024] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.
[0025] Those skilled in the art should understand that, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limiting this invention.
[0026] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.
[0027] refer to Figures 1 to 3 According to a preferred embodiment of the present invention, a three-dimensional fabric unit includes an upper layer 10, a middle layer 20 and a lower layer 30.
[0028] The intermediate layer 20 is a single coil or a single coil in the horizontal and vertical rows. The spacer wire specifications are a single bundle or a single strand with a thickness of 10dtex-300dtex, a single strand or a number of 1-90 strands, and a single bundle or a number of 1-90 yarns with a breaking strength of ≤7cN / dtex.
[0029] The upper layer 10 and the lower layer 30 are formed on the upper and lower sides of the intermediate layer 20 by weaving, wherein the yarn of the upper layer 10 and the lower layer 30 is a single bundle or a single strand with a f number, and its specification is selected as 20dtex-300dtex; wherein the single bundle or f number of the yarn is 1f-600f; the thickness of the single bundle or f number of the yarn is 0.03dtex-300dtex; and the breaking strength of the single bundle or f number of the yarn is ≤5cN / dtex.
[0030] Preferably, the intermediate layer 20, the upper layer 10 and the lower layer 30 are manufactured using yarn processes including at least one of FDY fully drawn yarn, DTY drawn textured yarn, BCF bulked continuous filament, and HOY highly oriented yarn.
[0031] Preferably, the yarn is made of fiber raw material, wherein the fiber raw material is selected from at least one of: polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber or polyvinyl alcohol formaldehyde fiber.
[0032] Preferably, the coil density of the upper layer 10 and the lower layer 30 is implemented as follows: 6-12 coils per centimeter of horizontal row and 10-30 coils per centimeter of vertical row.
[0033] Preferably, the density of the spacer yarns in the intermediate layer 20 is 120 to 64,800 per square centimeter.
[0034] Preferably, the thickness of the three-dimensional fabric is 1.2mm-20mm.
[0035] Preferably, the surface layer is formed by the following method: knitting of the front and rear needle beds in warp knitting, with the guide needle moving 0-2 needles horizontally once or continuously before the discarding needle hook, including both unidirectional and counter-directional padding knitting, and both open and closed padding knitting. The guide needle moves 0-4 needles horizontally once or continuously behind the discarding needle hook, including both unidirectional and counter-directional padding knitting, and both open and closed padding knitting.
[0036] Preferably, the intermediate layer 20 is formed in the following manner: During warp knitting of the front and rear needle beds, the guide needle moves 0-2 needles horizontally once or continuously before the discarding needle hook, including both unidirectional and counter-directional padding knitting, and both open and closed padding knitting. During the front and rear needle beds knitting, the guide needle moves 0-6 needles horizontally once or continuously behind the discarding needle hook, including both unidirectional and counter-directional padding knitting, and both open and closed padding knitting.
[0037] Preferably, the yarn threading method of the upper layer 10, the lower layer 30, and the middle layer 20 is: full threading or one threading and one gap through the yarn guide needle hole.
[0038] In a specific example, the three-dimensional fabric unit is prepared as shown in the table below:
[0039] Example 1
[0040] The intermediate layer 20, wherein the intermediate layer has a single coil or a single coil in the horizontal and vertical rows, and the spacer wire specifications are a single bundle or a single strand with a thickness of 10dtex-300dtex; a single strand or a number of 1-90 strands; and a yarn specification with a single bundle or a number of f and a breaking strength of ≤7cN / dtex.
[0041] The upper layer 10 and the lower layer 30 are formed by weaving on the upper and lower sides of the intermediate layer. The yarn of the upper layer and the lower layer is a single bundle or a single strand with a f number, and its specification is selected as 20dtex-300dtex. The single bundle or f number of the yarn is 1f-600f. The thickness of the single bundle or f number of the yarn is 0.03dtex-300dtex. The breaking strength of the single bundle or f number of the yarn is ≤5cN / dtex.
[0042] The intermediate layer, the upper layer, and the lower layer are manufactured using yarn processes including at least one of FDY fully drawn yarn, DTY drawn textured yarn, BCF bulked continuous filament, and HOY highly oriented spun yarn. The yarn is made from fiber raw materials selected from at least one of polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber, or polyvinyl alcohol formal fiber.
[0043] The coil density of the upper layer and the lower layer is implemented as follows: 6-12 coils per centimeter of horizontal row and 10-30 coils per centimeter of vertical row. The wire density is 120 to 64,800 wires per square centimeter.
[0044] The thickness of the three-dimensional fabric is 1.2mm-20mm.
[0045] It allows for flexible adjustment of fabric properties such as breaking strength, tear strength, surface fiber density, spacer fiber density, coil density, compressive stress (KPa), light transmittance, hand softness, elongation, dynamic elongation, temperature resistance during use, dimensional change, thickness change, bulkiness, and liquid carry-over rate.
[0046] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the invention. The advantages of the present invention have been fully and effectively realized. The functional and structural principles of the present invention have been demonstrated and explained in the embodiments; any variations or modifications can be made to the implementation of the present invention without departing from these principles.
Claims
1. A three-dimensional fabric unit, characterized in that, The three-dimensional fabric unit includes: Intermediate layer, wherein the intermediate layer is a single coil or a single coil in the horizontal and vertical rows, the spacer wire specification is a single bundle or a single strand, the thickness is 10dtex-300dtex: single strand or number of strands is 1-90: the yarn specification is a single bundle or number of strands, the breaking strength is ≤7cN / dtex; The upper and lower layers are formed by weaving on the upper and lower sides of the intermediate layer, wherein the yarn of the upper and lower layers is a single bundle or a single strand with a f number, and its specification is selected as 20dtex-300dtex; wherein the single bundle or f number of the yarn is 1f-600f; the thickness of the single bundle or f number of the yarn is 0.03dtex-300dtex; and the breaking strength of the single bundle or f number of the yarn is ≤5cN / dtex.
2. The three-dimensional fabric unit according to claim 1, characterized in that, The intermediate layer, the upper layer, and the lower layer are manufactured using yarn processes including at least one of FDY fully drawn yarn, DTY drawn textured yarn, BCF bulked continuous filament, and HOY highly oriented yarn.
3. The three-dimensional fabric unit according to claim 1, characterized in that, The yarn is made of fiber raw materials, wherein the fiber raw materials are selected from at least one of the following: polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyethylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber, or polyvinyl alcohol formaldehyde fiber.
4. The three-dimensional fabric unit according to claim 1, characterized in that, The coil density of the upper layer and the lower layer is implemented as follows: 6-12 coils per centimeter of horizontal row and 10-30 coils per centimeter of vertical row.
5. The three-dimensional fabric unit according to claim 1, characterized in that, The density of the spacer yarns in the intermediate layer is 120 to 64,800 per square centimeter.
6. The three-dimensional fabric unit according to claim 1, characterized in that, The thickness of the three-dimensional fabric is 1.2mm-20mm.
7. The three-dimensional fabric unit according to claim 1, characterized in that, The surface layer is formed by the following methods: knitting of the front and back needle beds of warp knitting, the guide needle moving 0-2 needles horizontally once or continuously before the discarding needle hook, including knitting with yarn padding in the same direction and opposite direction, knitting with yarn padding in open and closed directions, the guide needle moving 0-4 needles horizontally once or continuously behind the discarding needle hook, including knitting with yarn padding in the same direction and opposite direction, and knitting with yarn padding in open and closed directions.
8. The three-dimensional fabric unit according to claim 1, characterized in that, The intermediate layer is formed in the following manner: knitting of the front and rear needle beds, with the guide needle moving 0-2 needles horizontally once or continuously before the discarding needle hook, including knitting with yarn padding in the same and opposite directions, including knitting with yarn padding in open and closed directions, knitting of the front and rear needle beds, with the guide needle moving 0-6 needles horizontally once or continuously before the discarding needle hook, including knitting with yarn padding in the same and opposite directions, including knitting with yarn padding in open and closed directions.
9. The three-dimensional fabric unit according to claim 7 or 8, characterized in that, The yarn threading method for the upper layer, the lower layer, and the middle layer is as follows: the yarn is threaded through the yarn guide needle holes, either fully threaded or threaded through one hole and then left open.