A base cloth, artificial leather, automobile instrument panel interior and automobile

Abstract

The utility model relates to a base cloth, artificial leather, car instrument panel interior and car, the base cloth adopts the weft knitting structure of interlooping connection and is woven, in the base cloth, every unit length sets up N longitudinal rows and M columns, the longitudinal row is the unit structure of interlooping in the longitudinal direction of loop, and the column is the unit structure of connection in the horizontal direction of loop, wherein, the ratio range of N and M is 1 :(1.5~2). The warp breaking strength and weft breaking strength of the base cloth are roughly equivalent, and the artificial leather coated on the surface of the car instrument panel is made by adopting the base cloth, so that the air bag can be unfolded along the positive direction of the blasting impact force after blasting.

Description

Technical Field

[0001] This utility model relates to the field of automotive dashboard interiors, specifically to a base fabric, artificial leather, automotive dashboard interiors, and an automobile. Background Technology

[0002] Traditional automotive dashboards typically use polyvinyl chloride (PVC) or thermoplastic polyolefin (TPO) as the surface material. However, because airbags need to be installed within the dashboard, the surface material's strength cannot be too high, requiring a weakening process. From weakening to application, this involves mold development and verification, which is time-consuming and costly.

[0003] The new surface material for the dashboard can use non-weakening PVC, eliminating the need for mold development and reducing costs. The base fabric of this non-weakening PVC is weft-knitted fabric. Because the warp tensile strength of weft-knitted fabric is significantly greater than its weft tensile strength, during airbag deployment, the breakage often occurs not along the direction of the impact force, but rather tends to occur along the weft direction. Considering this, the directionality of the weft fabric's breakage needs to be taken into account when positioning the airbag (to ensure that the airbag's deployment direction accurately protects the occupants during deployment), which limits the airbag's placement within the dashboard and causes inconvenience for designers and developers. Utility Model Content

[0004] Based on the above situation, the main purpose of this utility model is to provide a base fabric, artificial leather, automotive dashboard interior, and automobile. The warp breaking strength of the base fabric is roughly equivalent to the weft breaking strength. Using this base fabric to make artificial leather covering the surface of the automotive dashboard enables the airbag to deploy in the positive direction of the blast impact force after explosion.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] In the first aspect, this utility model provides a base fabric, which is woven from a weft knitting structure in which coils are interlocked. In the base fabric, each unit length is provided with N longitudinal rows and M transverse rows. The longitudinal rows are unit structures formed by coils interlocking longitudinally, and the transverse rows are unit structures formed by coils connecting transversely. The ratio of N to M is in the range of 1:(1.5~2).

[0007] Optionally, the base fabric is arranged in a cycle unit of 4 rows, wherein the first and third rows are woven together using the first and second yarns, and the second and fourth rows are woven using only the first yarn. The first yarn serves as the ground yarn of the base fabric, and the second yarn serves as the loop yarn of the base fabric.

[0008] Optionally, within a loop unit of the base fabric, a fixed number of coils at intervals in the first and third rows form floats, and the floats located in the first and third rows are staggered in the longitudinal direction, and the floats are woven from the first yarn.

[0009] Optionally, in the direction of the columns, the coil corresponding to the floating line of the current row in the next row is an elongated holding coil.

[0010] Optionally, the base fabric has a transverse density of 27 rows / inch and a longitudinal density of 42 rows / inch.

[0011] Optionally, the first yarn has a specification of 75D and the second yarn has a specification of 50D.

[0012] Secondly, this utility model provides an artificial leather comprising a base fabric layer made of an upper base fabric.

[0013] Optionally, the artificial leather also includes a first PVC layer, a second PVC layer, and a PVC adhesive layer; wherein the multi-layer structure of the artificial leather is as follows: a first PVC layer, a second PVC layer, a PVC adhesive layer, and a base fabric layer.

[0014] Thirdly, this utility model provides an automotive dashboard interior, which is made of the artificial leather described above.

[0015] Fourthly, this utility model provides an automobile, including the aforementioned automobile dashboard interior.

[0016] like Figure 1 As shown, the base fabric provided by this invention, when subjected to warp tension, has two interlacing points on a unit warp, while when subjected to weft tension, it has only one interlacing point on a unit weft. That is, if the number of warp rows N per unit length is the same as the number of weft rows M, and there is no relative displacement between the yarns under stress, the warp breaking strength of the base fabric is approximately twice the weft breaking strength. To balance the warp and weft breaking strengths, the number of weft rows M per unit length is set to 2 to 1.5 times the number of warp rows N, compensating for the insufficient number of stress points by increasing the number of weft rows per unit length.

[0017] Other beneficial effects of this utility model will be explained in detail through the introduction of specific technical features and technical solutions in the specific embodiments. Those skilled in the art should be able to understand the beneficial technical effects brought about by the technical features and technical solutions through the introduction of these technical features and technical solutions. Attached Figure Description

[0018] The preferred embodiments of the present invention will now be described with reference to the accompanying drawings. In the drawings:

[0019] Figure 1 This diagram illustrates a base fabric weaving structure in an embodiment of the present invention.

[0020] Figure 2 This diagram shows a coil in the stress center region of this utility model before deformation occurs.

[0021] Figure 3 This invention illustrates an embodiment of the present invention. Figure 2 A schematic diagram of the deformation of a coil after it has bent and straightened;

[0022] Figure 4 This diagram illustrates the deformation of the base fabric with an increase in interlacing points per unit length in the longitudinal direction, as shown in an embodiment of the present invention.

[0023] Figure 5 This shows another schematic diagram of the base fabric weaving structure in an embodiment of the present invention;

[0024] Figure 6 This diagram illustrates the distribution of float wires and coils within a loop unit in an embodiment of the present invention.

[0025] Figure 7 This diagram illustrates the distribution of inner yarn and loop yarn in a recirculating unit according to an embodiment of the present invention.

[0026] Figure 8 A schematic diagram of the multi-layer structure of artificial leather in an embodiment of this utility model is shown;

[0027] Figure label:

[0028] 10. Column; A. First column; B. Second column; 20. Row; 201. First row; 202. Second row; 203. Third row; 204. Fourth row; 30. Float; 40. Lengthened holding loop; 50. Interlacing point; 60. Crooked section; 70. Ground yarn; 80. Loop yarn; 901. First PVC layer; 902. Second PVC layer; 903. Base fabric layer. Detailed Implementation

[0029] The present invention will now be described based on embodiments, but the present invention is not limited to these embodiments. In the following detailed description of the present invention, some specific details are described in detail, but well-known methods, processes, procedures, and elements are not described in detail in order to avoid obscuring the essence of the present invention.

[0030] Furthermore, those skilled in the art should understand that the accompanying drawings provided herein are for illustrative purposes only and are not necessarily drawn to scale.

[0031] Unless the context explicitly requires it, the words "comprising," "including," and similar terms throughout the specification and claims should be interpreted as encompassing rather than being exclusive or exhaustive; that is, meaning "including but not limited to."

[0032] In the description of this utility model, it should be understood that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0033] As mentioned earlier, airbags are installed inside the car dashboard. When the airbags deploy, they need to break through the artificial leather covering the dashboard surface and expand towards the occupants to protect them. Current solutions use non-weakening PVC as the artificial leather covering the dashboard surface. The main factor affecting its fracture direction is the base fabric of the artificial leather. Existing base fabrics are weft-knitted fabrics. Because the warp tensile strength of weft-knitted fabrics is significantly greater than its weft tensile strength, when subjected to an impact force perpendicular to the base fabric surface, it often fractures not along the direction of the impact force, but rather tends to fracture along the weft direction. This forces automotive developers to consider the fracture direction of the artificial leather when designing the airbag placement, limiting the freedom of airbag layout within the dashboard.

[0034] In view of this, the present invention proposes a base fabric for making artificial leather covering the surface of a car dashboard. The warp tensile strength of the base fabric is approximately equal to the weft tensile strength. Using this artificial leather as the material covering the surface of the car dashboard enables the airbag to deploy in the positive direction of the blast impact after it explodes.

[0035] In textile fabrics, the main factors affecting the breaking strength of the fabric include: the material of the yarn, the twist of the yarn, and the weave structure. For the same base fabric, the material and twist of the yarn are the same in both the warp and weft directions. This means that the difference between the warp and weft breaking strength mainly stems from the weave structure. Please refer to [link / reference]. Figures 1 to 8 This utility model provides a base fabric woven from a weft-knitted structure in which coils are interlocked. The base fabric includes multiple warp rows 10 and multiple transverse rows 20. Specifically, each unit length has N warp rows 10 and M transverse rows 20, where each warp row 10 is a unit structure formed by interlocking coils longitudinally, and each transverse row 20 is a unit structure formed by connecting coils transversely. The ratio of N to M ranges from 1:(1.5 to 2).

[0036] like Figure 1As shown, the base fabric provided by this utility model, when subjected to warp tension, has two interlacing points 50 on a unit warp length, while when subjected to weft tension, only one interlacing point 50 on a unit weft length is subjected to tension. That is, assuming the number of warp lengths N per unit length is the same as the number of weft lengths M, and no relative displacement occurs between the yarns under stress, the warp breaking strength of the base fabric is approximately twice the weft breaking strength. To balance the warp and weft breaking strengths, the number of weft lengths M per unit length is set to 1.5 to 2 times the number of warp lengths N, compensating for the insufficient number of stress points by increasing the number of weft lengths per unit length.

[0037] Specifically, please refer to Figures 2 to 4 The force analysis for "compensating for the insufficient number of force points by increasing the number of rows per unit length" is as follows:

[0038] Please see Figure 2 and Figure 3 , Figure 2 This diagram shows a coil in the center of force region before deformation. Figure 3 Show Figure 2 The diagram illustrates the deformation of a coil after it has buckled and straightened. For a single coil, if both sides are subjected to latitudinal tensile force, the buckled portion 60 of the coil begins to straighten. The interlacing point 50 within the straightening coil begins to bear force, and the coil begins to deform longitudinally (equivalent to the single coil being compressed longitudinally). At this point, the latitudinal tensile force is converted into a roughly longitudinal force and transmitted to the upper and lower directions of the current coil. In other words, the latitudinal fracture strength mainly considers the number of stress points per unit length in the longitudinal direction.

[0039] On the one hand, during the weaving stage, please refer to Figure 4 The more rows of coils are arranged per unit length (i.e., the greater the longitudinal density), the smaller the circumference of a single coil, and the easier it is for the coil to straighten. Only after the bending is basically straightened does the interlacing point 50 begin to bear the force. After bearing the force, the tensile force can be distributed. The more interlacing points 50 that participate in bearing the force, the greater the weft breaking strength of the base fabric.

[0040] On the other hand, during the latitudinal tensile force stage, the coils in the center of the force region begin to deform first. The resulting meridional force then propagates to the upper and lower sides of the coils, causing the coils near the center of the force region to converge towards it. In other words, the number of interlacing points 50 participating in the force distribution per unit length in the longitudinal direction also increases (it should be noted that due to tensile deformation, the number of additional force-bearing points per unit length in the longitudinal direction may not be as significant as the original number of force-bearing points). Figure 4So even though they are on the same straight line in the longitudinal direction, they can still play a role in sharing the tensile force. Therefore, considering that when the base fabric is stretched in the weft direction, the interlacing point 50 will gather towards the center of the force, the number of rows M does not need to be set to twice the number of columns N. It can be set to 1.5 times to 2 times the number of columns N according to the actual situation (e.g., the material of different yarns will affect the gathering, the distribution of floats 30 and the buckling length of the loops will also affect the gathering).

[0041] Continue reading Figure 1 The base fabric of this invention uses four horizontal rows as a repeating unit. The first horizontal row 201 and the third horizontal row 203 are woven together using both the first and second weaving threads, while the second horizontal row 202 and the fourth horizontal row 204 are woven using only the first weaving thread. Figure 1 In the diagram, dark lines represent the first weave thread, and light lines represent the second weave thread. For details, please refer to [link / reference]. Figure 5 The first yarn serves as the ground yarn 70 of the base fabric, and the second yarn serves as the loop yarn 80 of the base fabric. In knitted fabrics, the ground yarn 70 refers to the yarn that forms the basic structure of the fabric, usually used to constitute the base structure of the fabric. The ground yarn 70 plays a supporting and fixing role in the base fabric of this invention and is the basic part of the mechanical properties of the base fabric. In knitted fabrics, the loop yarn 80 is a type of fancy yarn, characterized by the formation of regular raised loops on the surface of the ground yarn 70 during the knitting process. In the embodiment of this invention, the loop yarn 80 is equivalent to the raised pile on the surface of the base fabric. When making artificial leather, the loop yarn 80 can increase the bonding surface area with the PVC adhesive layer, so that the base fabric can better bond with the PVC layer. In one embodiment, the first yarn is made of 75D drawn textured yarn (DTY) polyester material, and the second yarn is made of 50D drawn textured yarn (DTF) polyester material.

[0042] For details, please refer to [link / reference]. Figure 1 In this embodiment of the invention, within a loop unit of the base fabric, the first row 201 and the third row 203 form floats 30 by a fixed number of loops at intervals. The floats 30 are woven from the first yarn. Furthermore, the floats 30 located on the first row 201 and the third row 203 are staggered in the longitudinal direction; that is, floats 30 will not appear simultaneously on the same longitudinal line within a loop unit. Forming floats 30 by a fixed number of loops at intervals reduces the weft stretch of the base fabric, thereby improving the dimensional stability of the base fabric. Moreover, since loops are not required at the locations of the floats 30, small indentations will form at the locations of the floats 30 on the base fabric plane formed by the ground yarn 70. (Continue reading...) Figure 1 On the first row 201 and the third row 203, the position adjacent to the float 30 is exactly the loop yarn 80 formed by the second weaving. Since the loop yarn 80 itself is a raised loop on the base fabric plane, the combination of the loop yarn 80 and its adjacent float 30 makes the sinking arc of the loop yarn longer (that is, to form a greater drop in the thickness direction), so that the base fabric can have a better textured nap effect without subsequent processing.

[0043] Further reading Figure 1 In this embodiment of the invention, the float wire 30 in the current row corresponds to the elongated grip coil 40 in the next row. For example, assuming the current row is the first row 201 and the next row is the second row 202, in the first column A of the figure, the first row 201 is the float wire 30, and the second row 202 is the elongated grip coil 40. Figure 1 As shown, the elongated holding coil 40 of the second row 202 spans the first row 201 and the second row 202. The elongated holding coil 40 can improve the extensibility and elasticity of the base fabric, allowing the base fabric to better recover its original shape after stretching.

[0044] In one specific implementation, the base fabric is woven on a 19-needle, 30-inch tube terry cloth loom. The ground yarn 70 is made of 75D / 36F DTY filament, and the loop yarn 80 is made of 50D / 48F DTF filament. In this embodiment, the matching of raw materials and machine size is fine yarn with coarse needles, resulting in a sparser weave in the base fabric, which reduces the overall breaking strength and makes the airbag easier to burst successfully. Two yarn feeders are used during weaving: one feeds into both the loop yarn 80 and the ground yarn 70, and the other feeds only into the ground yarn 70, performing weft knitting variations (i.e., staggered spacing between the ground yarn 70 and the loop yarn 80, and the formation of floats 30 at fixed intervals). Please refer to [link to relevant documentation]. Figure 1 , Figure 6 and Figure 7The ground yarn 70 and the loop yarn 80 are used together to weave the first row 201 and the third row 203. The ground yarn 70 is used to weave the second row 202 and the fourth row 204. Floats 30 are added only to the first row 201 and the third row 203, with one float 30 placed every other loop in each row 201 and the third row 203. Within a cycle unit, the positions of the floats 30 are staggered in the longitudinal direction. In the first longitudinal row A of the diagram, the first row 201 is a float 30, and the second row 202 is a stretched holding loop 40. In the second longitudinal row B of the diagram, the third row 203 is a float 30, and the fourth row 204 is a stretched holding loop 40. In the base fabric of this embodiment, only the front side of the base fabric has loop yarn 80, while the reverse side is entirely ground yarn 70. The elongated gripping loops are only present at the ground yarn 70, forming a terry cloth base fabric with a dot-matrix textured plush effect. Furthermore, the presence of float yarn 30 further lengthens the sinker arc of the loop yarn 80, making the base fabric have a more pronounced plush effect. Moreover, the weaving method of fine yarn with coarse needles increases the porosity of the base fabric, forming a more obvious mesh, making the base fabric thinner and lighter, and increasing the difference in warp and weft density and the extensibility of the weft direction, thus balancing the deformability of the base fabric. The performance test parameters of the base fabric in this embodiment are as follows:

[0045] Table 1. Base Fabric Performance Test Data

[0046]

[0047]

[0048] This embodiment of the invention also provides an artificial leather, which includes a base fabric layer 903 made from the aforementioned base fabric. Specifically, please refer to... Figure 8 The artificial leather comprises, in sequence: a first PVC layer 901, a second PVC layer 902, a PVC adhesive layer (not shown in the attached figure), and a base fabric layer 903.

[0049] Specifically, the first PVC layer 901 is the surface layer of the artificial leather, giving it a leather-like texture. The surface of the first PVC layer 901 can also be enhanced through embossing or other methods. The first PVC layer 901 is made of 90-110 parts PVC powder, 85-95 parts dioctyl phthalate (plasticizer), 4-6 parts calcium carbonate, 2-4 parts calcium-zinc stabilizer, and 3-5 parts colorant. The first PVC layer 901 using the above formula also has a good hand feel, and the PVC layer itself exhibits good strength. Preferably, the first PVC layer 901 is made by mixing 100 parts PVC powder, 90 parts dioctyl phthalate (plasticizer), 5 parts calcium carbonate, 3 parts calcium-zinc stabilizer, and 4 parts colorant.

[0050] Specifically, the second PVC layer 902 is a foamed buffer layer for artificial leather. This second PVC layer is composed of 90-110 parts PVC powder, 85-95 parts dioctyl phthalate (plasticizer), 4-6 parts calcium carbonate, 4-6 parts stabilizer, 1-3 parts azodicarbonamide (foaming agent), 4-8 parts antimony trioxide powder, and 0.5-1.5 parts colorant. The main function of this second PVC layer 902 is to further improve the strength of the PVC material layer. Antimony trioxide is also added to the second PVC layer 902 as a flame retardant, which improves the flame retardant effect of the artificial leather. However, considering that antimony trioxide easily precipitates and floats on the surface, it is not added to the first PVC layer 901. Colorant is also added to the second PVC layer 902 to further mask the colors of the underlying base fabric layer 903 and other structural layers (if any), allowing the artificial leather to present its ideal color as fully as possible. Preferably, the second PVC layer 902 is made by mixing 100 parts of PVC powder, 80 parts of plasticizer dioctyl phthalate, 5 parts of calcium carbonate, 5 parts of calcium zinc stabilizer, 2 parts of foaming agent azodicarbonamide, 6 parts of antimony trioxide powder and 1 part of colorant.

[0051] Specifically, the main function of the PVC adhesive layer (not shown in the attached diagram) is to firmly bond the base fabric layer 903 to the second PVC layer. The PVC adhesive layer is located above the base fabric layer 903 and below the second PVC layer. It is composed of 90-110 parts PVC powder, 85-95 parts dioctyl phthalate (plasticizer), and 1-3 parts calcium-zinc stabilizer. It is important to note that the PVC adhesive layer is typically thin, requiring only a light application, to avoid excessive adhesive application that could cause the PVC material layer to harden. Preferably, the adhesive layer is composed of 100 parts PVC powder, 80 parts dioctyl phthalate (plasticizer), and 2 parts calcium-zinc stabilizer.

[0052] In this embodiment of the invention, the artificial leather uses the aforementioned base fabric as the base layer. The warp and weft tensile strengths of this base fabric are essentially the same. Therefore, when subjected to an impact force perpendicular to the surface of the artificial leather, the fracture direction will not tilt in either the warp or weft direction. Consequently, when the airbag deploys, it can unfold in the direction of the impact force, giving automotive R&D personnel more freedom in designing the airbag's placement. The following are the performance test parameters of the artificial leather in this embodiment:

[0053] Table 2 Performance test data of artificial leather

[0054]

[0055] Furthermore, this utility model also provides an automotive dashboard interior trim, which is made of artificial leather as described above. Specifically, in this embodiment of the utility model, the surface of the automotive dashboard is covered with the artificial leather described in the above embodiments. The relevant properties of the base fabric and the artificial leather can be referred to in the above embodiments, and will not be repeated here.

[0056] Furthermore, this utility model provides a car, including the car dashboard interior as described above. The surface of the car dashboard in this car is covered with artificial leather as described in the above embodiments, wherein the relevant properties of the base fabric and artificial leather can be referred to in the above embodiments, and will not be repeated here.

[0057] Those skilled in the art will understand that, without conflict, the above-mentioned preferred solutions can be freely combined and superimposed. It should be noted that the use of step numbers (letters or numbers) to refer to certain specific method steps in this invention is merely for the purpose of convenience and brevity, and is by no means intended to restrict the order of these method steps. Those skilled in the art will understand that the order of the relevant method steps should be determined by the technology itself and should not be unduly restricted by the existence of step numbers. Those skilled in the art can determine various permissible and reasonable orderings of steps based on the technology itself.

[0058] It is particularly important to note that the selection of these specific values, the relationships between them, and the ranges of values ​​requires not only a theoretical foundation far exceeding that of ordinary technicians in the field, but also creative attempts and selections based on the expected target design results, supplemented by several arduous experiments, in order to finally obtain the expected target results.

[0059] Those skilled in the art will understand that, without conflict, the above-mentioned preferred solutions can be freely combined and superimposed.

[0060] It should be understood that the above-described embodiments are merely exemplary and not restrictive. Without departing from the basic principles of this utility model, any obvious or equivalent modifications or substitutions made by those skilled in the art regarding the above details will be included within the scope of the claims of this utility model.

Claims

1. A base fabric, characterized in that, The base fabric is woven using a weft knitting structure in which coils are interlocked. In the base fabric, each unit length has N longitudinal rows and M transverse rows. The longitudinal rows are unit structures formed by the coils interlocking longitudinally, and the transverse rows are unit structures formed by the coils connecting transversely. The ratio of N to M is in the range of 1:(1.5~2).

2. The base fabric according to claim 1, characterized in that, The base fabric is arranged in a cycle unit of 4 horizontal rows. The first and third horizontal rows are woven together using the first and second yarns, while the second and fourth horizontal rows are woven using only the first yarn. The first yarn serves as the ground yarn of the base fabric, and the second yarn serves as the loop yarn of the base fabric.

3. The base fabric according to claim 2, characterized in that, Within a loop unit of the base fabric, the first and third rows form floats at fixed intervals by a fixed number of coils, and the floats located on the first and third rows are staggered in the longitudinal direction. The floats are woven from a first yarn.

4. The base fabric according to claim 3, characterized in that, In the vertical direction, the coil corresponding to the floating line of the current row in the next row is the extended holding coil.

5. The base fabric according to claim 3, characterized in that, The base fabric has a transverse density of 27 rows / inch and a longitudinal density of 42 rows / inch.

6. The base fabric according to claim 2, characterized in that, The first yarn has a specification of 75D, and the second yarn has a specification of 50D.

7. A type of artificial leather, characterized in that, The artificial leather comprises a base fabric layer made from the base fabric of any one of claims 1-6.

8. The artificial leather according to claim 7, characterized in that, The artificial leather further includes a first PVC layer, a second PVC layer, and a PVC adhesive layer; wherein the multi-layer structure of the artificial leather is as follows: The first PVC layer, the second PVC layer, the PVC adhesive layer, and the base fabric layer.

9. An automotive dashboard interior, characterized in that, The interior of the vehicle dashboard is made of artificial leather as described in any one of claims 7-8.

10. A car, characterized in that, Including the automotive dashboard interior as described in claim 9.

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