Fabric and automotive interior material

Abstract

The utility model provides a kind of fabric and car interior material, wherein the fabric includes: base material layer is made of fiber, pile layer is made of multiple silk velvet arrangement, and silk velvet is connected base material layer respectively, composite coating is located on the surface of base material layer, at least a part of multiple silk velvet is exposed to the surface of composite coating, at least a part of multiple silk velvet is exposed to composite coating, so that the fabric surface formed still has velvet layer, to increase the softness and comfort of fabric, improve the touch feeling;And the setting of composite coating can also provide additional protection and functionality, such as wear resistance, stain resistance, etc., enhance the comprehensive performance of fabric, so that it can meet the needs of various use scenarios.

Description

Technical Field

[0001] This utility model relates to the field of fabrics, specifically to a fabric and automotive interior material. Background Technology

[0002] In the automotive interior design field, the choice of headliner material plays a crucial role in enhancing the comfort and aesthetics of a vehicle. Traditional printed needle-punched nonwoven fabric for automotive headliners is typically used in lower-end models due to its cost-effectiveness and production efficiency. However, this material has several limitations in raw material selection, product structure, production process, and application performance, restricting its application in high-end models. One reason is its relatively rough feel, lacking softness and comfort. Another reason is that the surface of the nonwoven fabric is completely sealed with a resin layer, resulting in a loss of its plush texture.

[0003] Therefore, how to improve the performance of fabrics so that they can be used in automotive interiors is an urgent problem to be solved. Utility Model Content

[0004] The problem solved by this utility model is to provide a fabric and automotive interior material that ensures the surface of the fabric still has a nap layer and a rich and delicate feel, thus making it suitable for higher-end models.

[0005] To address the aforementioned problems, this utility model provides a fabric comprising: a substrate layer made of fibers; a pile layer composed of multiple bundles of velvet arranged together, wherein the velvet bundles are respectively connected to the substrate layer; and a composite coating located on the surface of the substrate layer, wherein at least a portion of the multiple bundles of velvet are exposed on the surface of the composite coating.

[0006] Optionally, multiple bundles of the velvet may pass through the composite coating.

[0007] Optionally, the substrate layer is needle-punched nonwoven fabric, hot-air nonwoven fabric, spunbond nonwoven fabric, or felt.

[0008] Optionally, the fiber fineness is 1.3 denier to 1.7 denier, and the fiber length is 35 mm to 40 mm.

[0009] Optionally, the fiber is PET fiber, PBT fiber, PTT fiber, PEN fiber, nylon fiber or acrylic fiber.

[0010] Optionally, the fiber is a colored fiber.

[0011] Optionally, the composite coating is a composite layer of a resin layer and a softening layer located on the surface of the substrate layer.

[0012] Optionally, the composite coating is a composite layer consisting of a resin layer, a softening layer, and a printing layer located on the surface of the substrate layer.

[0013] Optionally, the thickness of the fabric ranges from 1.4 mm to 1.6 mm.

[0014] Optionally, the plurality of velvets are coil-shaped, with both ends connected to the substrate layer.

[0015] Optionally, the top ends of the plurality of velvets away from the substrate layer are curved ends, which expose the surface of the composite coating.

[0016] Optionally, the plurality of velvets are strips, with one end of each strip attached to the substrate layer.

[0017] Accordingly, this utility model provides an automotive interior material, comprising at least one layer of any of the above-mentioned fabrics.

[0018] Optionally, a support layer may also be included on the surface of the substrate layer, wherein the support layer and the composite coating are located on opposite surfaces of the substrate layer.

[0019] Optionally, the material of the support layer is sponge or non-woven fabric.

[0020] Compared with the prior art, the technical solution of this utility model has the following advantages:

[0021] In the fabric provided by this technical solution, the base layer is made of fibers, the pile layer is composed of multiple bundles of velvet arranged together, and the velvets are connected to the base layer respectively. The composite coating is located on the surface of the base layer, and at least a portion of the multiple bundles of velvet exposes the surface of the composite coating. By utilizing the exposure of at least a portion of the multiple bundles of velvet to the composite coating, the surface of the formed fabric still has a pile layer, thereby increasing the softness and comfort of the fabric and improving the tactile feel. Furthermore, the composite coating can also provide additional protection and functionality through the coating, such as abrasion resistance and stain resistance, enhancing the overall performance of the fabric and enabling it to meet the needs of various usage scenarios.

[0022] Furthermore, the fibers have a fineness of 1.3 to 1.7 denier and a length of 35 mm to 40 mm. Fibers of this specification can be better interwoven during processing to form a uniform and dense fiber layer. This not only improves the strength and abrasion resistance of the fabric but also ensures the softness and fluffiness of the fiber layer, making the fabric less prone to deformation during use while maintaining a good feel and appearance. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the fabric structure in one embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of the fabric structure in another embodiment of the present invention. Detailed Implementation

[0025] The poor feel of the fabrics currently used in automotive interiors limits their application range to some extent.

[0026] Based on this, this technical solution proposes a fabric and automotive interior material, wherein the fabric includes: a base layer made of fibers, a pile layer composed of multiple bundles of velvet arranged together, with the velvets respectively connected to the base layer, and a composite coating located on the surface of the base layer. At least a portion of the multiple bundles of velvet exposes the surface of the composite coating. By utilizing the exposure of at least a portion of the multiple bundles of velvet to the composite coating, the resulting fabric surface still has a pile layer, thereby increasing the softness and comfort of the fabric and improving the tactile feel. Furthermore, the composite coating can also provide additional protection and functionality through the coating, such as abrasion resistance and stain resistance, enhancing the overall performance of the fabric and enabling it to meet the needs of various usage scenarios.

[0027] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0028] First, please refer to Figure 1 A fabric 100 includes a substrate layer 101 and a composite coating 102.

[0029] In this embodiment, the substrate layer 101 is made of fiber, and the surface of the substrate layer 101 has multiple bundles of velvet 101-1. The pile layer is composed of multiple bundles of velvet 101-1 arranged together, and the velvet 101-1 are respectively connected to the substrate layer 101. The surface of the substrate layer 101 has a composite coating 102, and at least a portion of the multiple bundles of velvet 101-1 exposes the surface of the composite coating 102.

[0030] In this embodiment, the velvet 101-1 on the surface of the substrate layer 101 is directly used as the pile layer, instead of forming the pile layer through flocking later. This not only ensures the strength of the pile layer and prevents the pile from falling off, but also eliminates the need for additional glue for pile adhesion, simplifying the process, reducing costs, and making it more environmentally friendly.

[0031] In this embodiment, the substrate layer 101 is a needle-punched nonwoven fabric. Needle-punched nonwoven fabric has high strength, and even a relatively thin substrate layer 101 can meet the strength requirements of the final fabric 100. Combined with the composite coating 102, a portion of the velvet 101-1 on the surface of the substrate layer 101 is exposed and directly used as a pile layer. This ensures that the formed fabric 100 not only has a suitable thickness, but also guarantees its strength, good tear resistance, light resistance, excellent abrasion resistance, and full touch. It can also be widely used in automotive interior materials, including but not limited to headliners, sunroofs, door panels, etc., making it more suitable for use in automotive interiors.

[0032] In this embodiment, multiple strands of the velvet 101-1 pass through the composite coating 102 respectively. The purpose is to ensure that after the composite coating 102 is formed, the surface of the composite coating 102 will still have the velvet 101-1, thereby ensuring the velvet feel of the fabric 100 surface and improving the texture of the fabric 100.

[0033] In other embodiments, the substrate layer 101 may also be a hot-air nonwoven fabric, a spunbond nonwoven fabric, or a felt.

[0034] In this embodiment, the plurality of velvets 101-1 are coil-shaped, and both ends are connected to the substrate layer 101. The top ends of the plurality of velvets 101-1 away from the substrate layer 101 are curved ends, and the curved ends expose the surface of the composite coating 102.

[0035] In other embodiments, please refer to Figure 2 Each of the multiple velvets 101-1 is strip-shaped, and one end of each strip is connected to the substrate layer 101.

[0036] In this embodiment, the fiber fineness is 1.3 to 1.7 denier, and the fiber length is 35 mm to 40 mm. Fibers of this specification can be better interwoven during processing to form a uniform and tightly packed velvet 101-1. This not only improves the strength and abrasion resistance of the fabric 100 but also ensures the softness and fluffiness of the velvet 101-1, making the fabric 100 less prone to deformation during use while maintaining a good feel and appearance.

[0037] Preferably, the fiber has a length of 38 mm and a fineness of 1.5D.

[0038] In this embodiment, the fiber is PET fiber. PET fiber has high strength and abrasion resistance, which allows the fabric 100 to withstand greater friction and tension during use, making it less prone to wear and breakage. In applications such as automotive interiors, this high strength and abrasion resistance can significantly extend the service life of the fabric 100, reducing replacement frequency and maintenance costs. Simultaneously, PET fiber has excellent elastic recovery capabilities, maintaining its original shape and size even after prolonged use and repeated stretching and compression. This ensures that the fabric 100 is not easily deformed during use, maintaining a consistently good appearance and feel.

[0039] In other embodiments, the fiber may also be PBT fiber, PTT fiber, PEN fiber, nylon fiber, or acrylic fiber.

[0040] In this embodiment, the fiber is a colored fiber. Using colored fibers allows for direct color addition during the fiber production process, avoiding subsequent dyeing steps, thereby reducing production costs and environmental impact. Simultaneously, the color of colored fibers is more uniform and stable, less prone to fading, ensuring that fabric 100 maintains a good appearance during long-term use, thus improving the product's aesthetics and lifespan.

[0041] In this embodiment, the composite coating 102 is a composite layer consisting of a resin layer 102-1, a softening layer 102-2, and a printing layer 102-3 located on the surface of the substrate layer 101. This allows the fabric 100 to not only provide protection and softening but also to achieve personalized pattern designs through the printing layer 102-3, satisfying the aesthetic needs of different users. This multi-layer composite coating 102 design ensures the functionality and comfort of the fabric 100 while increasing its decorative and aesthetic appeal, thereby enhancing the added value of the product and expanding the application areas of the fabric 100.

[0042] It should be noted that, after the actual production process, the substrate layer 101 and the composite coating 102 in the fabric 100 have fused together, and there is no obvious dividing line. Figure 1 The layers are clearly defined so that the substrate layer 101 and the composite coating layer 102 can be clearly seen.

[0043] In other embodiments, the composite coating 102 is a composite layer of a resin layer and a softening layer located on the surface of the substrate layer 101. This not only provides excellent protection against abrasion and stains, but also makes the fabric 100 surface smoother and improves its feel. This composite coating 102 design allows the fabric 100 to maintain its functionality while remaining soft and comfortable, meeting the high requirements for touch and appearance in various fields.

[0044] In this embodiment, the thickness of the fabric 100 ranges from 1.4mm to 1.6mm. This ensures that the fabric 100 has sufficient strength and thickness to meet the support and protection requirements of use scenarios such as automotive interiors, while also avoiding excessive weight that would affect its softness and comfort. This thickness range allows the fabric 100 to maintain a good feel and appearance during use, while also adapting to different installation spaces and structural requirements.

[0045] In this embodiment, the formation process of the fabric 100 includes: unpacking and removing the fiber raw materials from the packaging; combing the fibers neatly to ensure even distribution; fixing the fibers into a semi-finished substrate layer 101 using a needle-punching process; and using barbed needles to move up and down to entangle the fibers, forming a substrate layer 101 with a certain strength and thickness. At this point, the surface of the substrate layer 101 has a fluffy fiber texture. Then, a resin slurry is used to coat the semi-finished base fabric. The resin slurry may be used to increase the strength, abrasion resistance, or other specific properties of the base fabric. A softening finishing layer is then applied to the surface, pressing the first resin layer from the surface to the center of the velvet 101-1. The softening finishing layer makes the fabric surface softer and also helps improve the fabric's hand feel. The treated fibers exhibit a soft, fluffy texture.

[0046] In this utility model, Sample 1 uses 1.5 denier (D) PET colored fiber with a fiber length of 38mm. Specifically, after the fiber is unpacked, it is first combed neatly, then fixed into a semi-finished substrate layer 101 by needle punching and rolled up. At this time, multiple bundles of velvet 101-1 are formed on the surface of the substrate layer 101. Subsequently, two printing processes are used in conjunction with a mesh screen for surface coating. The first process uses resin paste coating, and the second process uses a softening layer to squeeze the resin layer into the middle of the velvet 101-1. Then, it is dried by hot air blowing in an oven in a non-contact manner to ensure that the upper layer of plush fibers remains on the surface. After that, a surface printing process is carried out to make the surface present a specific pattern texture, making a printed non-woven fabric skin. Finally, it is heat-pressed at 180℃ to make the fabric surface smooth and soft and control the product thickness, resulting in a high-touch printed fabric 100.

[0047] The comparison sample used 3-denier PET colored fiber with a fiber length of 51mm. After the fiber was unpacked, it was first combed neatly, then fixed into a semi-finished substrate layer by needle punching and rolled up. Subsequently, a two-stage printing process was used in conjunction with a blank screen for surface coating. The first stage was a resin paste coating, and the second stage was a softening layer. At this point, the resin paste coating and the softening layer were completely covered on the semi-finished substrate layer, resulting in a smooth surface. The substrate layer was then dried in an oven, followed by a surface printing process to create a specific pattern and texture on the surface, producing a printed non-woven fabric outer skin. Finally, it was heat-pressed at 180℃ to obtain the final product.

[0048] The weight, thickness, tensile strength, elongation, and tear strength of the sample prepared according to this invention were tested compared with those of the control sample. The test results are shown in Table 1 below.

[0049] In this embodiment, the tensile strength and elongation tests were performed according to GB / T3923.1-2013, and the tear strength test was performed according to GB-T 3917.3-2009.

[0050] As shown in Table 1, the fabric of Sample 1 has a weight of 185.4 g / m², which is relatively light. This means that while maintaining a certain strength, it provides better softness and comfort, making it suitable for applications requiring lightweight materials, such as clothing and home décor. Its thickness is 1.42 mm, thinner than the comparison sample. This may help provide a softer touch while reducing material usage and lowering costs. Meanwhile, in the machine direction (MD), Sample 1 has a tensile strength of 346.45 N / 50 mm, which, although lower than the comparison sample, still exhibits good tensile properties. Furthermore, in the cross direction (CD), Sample 1 has a tensile strength of 290.55 N / 50 mm, showing a certain tensile capacity in different directions, making it suitable for applications requiring a certain level of tensile strength. Sample 1 has a tear strength of 58.68 N in the machine direction (MD), indicating a certain tear resistance, and in the cross direction (CD), Sample 1 has a tear strength of 52.07 N, showing a certain tear resistance in different directions, making it suitable for applications requiring a certain level of tear resistance.

[0051] In summary, the lightweight and thin profile of Sample 1 gives it an advantage in applications requiring weight reduction and space saving. Furthermore, Sample 1 performs better in terms of cost-effectiveness, flexibility, comfort, environmental impact, specific performance requirements, processability, and design flexibility. Therefore, the experiment concludes that Sample 1 is more favored in specific application scenarios due to its unique advantages, especially where there are special requirements for weight and thickness.

[0052] Table 1 shows the fabric performance test results.

[0053]

[0054] Accordingly, this utility model also provides an automotive interior material, comprising at least one layer of fabric 100 as described in any of the above claims.

[0055] In this embodiment, a support layer is also included on the surface of the substrate layer 101, and the support layer and the composite coating 102 are respectively located on opposite surfaces of the substrate layer 101.

[0056] In this embodiment, the material of the support layer is sponge or non-woven fabric. When the support layer is made of sponge, flame bonding is used to bond the support layer to the substrate layer 101. When the support layer is made of non-woven fabric, adhesive bonding can be used to bond the support layer to the substrate layer 101.

[0057] In this embodiment, a sponge is used as a support layer. The sponge can provide good cushioning and support, so that the interior materials can better restore their original shape when subjected to external force, avoid deformation, and ensure the overall performance and texture of the car interior.

[0058] Of course, in some embodiments, the support layer may also be made of other foaming materials, etc.

[0059] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A fabric, characterized in that, include: Substrate layer, the substrate layer being made of fibers; A pile layer, wherein the pile layer is composed of multiple bundles of velvet arranged together, and the velvets are respectively connected to the substrate layer; A composite coating is located on the surface of the substrate layer, and at least a portion of the multiple bundles of velvet exposes the surface of the composite coating.

2. The fabric as described in claim 1, characterized in that, Multiple strands of the velvet pass through the composite coating respectively.

3. The fabric as described in claim 1, characterized in that, The substrate layer is needle-punched nonwoven fabric, hot-air nonwoven fabric, spunbond nonwoven fabric, or felt.

4. The fabric as described in claim 1, characterized in that, The fiber has a fineness of 1.3 denier to 1.7 denier and a length of 35 mm to 40 mm.

5. The fabric as described in claim 1, characterized in that, The fiber is PET fiber, PBT fiber, PTT fiber, PEN fiber, nylon fiber, or acrylic fiber.

6. The fabric as described in claim 1, characterized in that, The fiber is a colored fiber.

7. The fabric as described in claim 1, characterized in that, The composite coating is a composite layer of a resin layer and a softening layer located on the surface of the substrate layer.

8. The fabric as described in claim 1, characterized in that, The composite coating is a composite layer consisting of a resin layer, a softening layer, and a printing layer located on the surface of the substrate layer.

9. The fabric as described in claim 1, characterized in that, The thickness of the fabric ranges from 1.4 mm to 1.6 mm.

10. The fabric as described in claim 1, characterized in that, The plurality of velvets are coil-shaped, and both ends are connected to the substrate layer.

11. The fabric as described in claim 2, characterized in that, The top ends of the plurality of velvets away from the substrate layer are curved ends, which expose the surface of the composite coating.

12. The fabric as described in claim 1, characterized in that, The plurality of velvet strands are strips, with one end of each strand attached to the substrate layer.

13. An automotive interior material, characterized in that, It includes at least one layer of fabric as described in any one of claims 1 to 12.

14. The automotive interior material as described in claim 13, characterized in that, It also includes a support layer located on the surface of the substrate layer, wherein the support layer and the composite coating are located on opposite surfaces of the substrate layer.

15. The automotive interior material as described in claim 14, characterized in that, The material of the support layer is sponge or non-woven fabric.

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