Ev automobile and weft knitted pile fabric

Abstract

To obtain a pile fabric suitable for EV automobile foot mat, which is three-dimensionally shaped and does not cause a phenomenon of grinning that discloses pile roots (13) at external corners (3) generated on a pile surface (12), and has a water barrier property to retain spilled drinking water and the like in a pile layer (21) for a short while without allowing the drinking water and the like to permeate immediately.SOLUTION: Weft (18) is knitted into a plain-knitted structure in a weft knitted base fabric (15). A weft knitted pile fabric (16) is formed by knitting a pile yarn (17) into the weft knitted base fabric. Clearance (α) between two piles adjacent in a course direction is below 0.38 cm. Clearance (β) between two piles adjacent in a wale direction is below 0.25 cm. Pile density (Θ) per unit area (10×10 cm2) is 1050 piles or more. "Standard pile fiber basis weight" (δ) per unit depth 1 cm and unit area 100 cm2 of the pile layer is 5 g / 100 cm3 or more.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a pile fabric that is suitable for carpets and EV car foot mats that can be easily applied along uneven surfaces such as the footwell of an automobile, do not cause greening in corners, and are difficult for spilled liquids to penetrate, wallpaper and other interior materials that have excellent heat retention, insulation, sound absorption, soundproofing, moisture retention, moisture absorption and adhesive application properties, and sheets and curtains that can withstand high-temperature sterilization treatment without deformation and are suitable for use in nursing homes and hospital rooms, and that is easy to fold and can be easily packed and stored in a compact package. [Background technology]

[0002] Pile fabrics include woven pile fabrics, warp knitted pile fabrics, weft knitted pile fabrics, and tufted pile fabrics. Carpets are laid on the floor below the floor and are used by walking on them, so tufted pile fabrics or woven pile fabrics using thick pile yarns such as those with a single fiber fineness of 17 "standard dtex" and a total fineness of 1365 "standard dtex" (see, for example, Patent Document 1) or a single fiber fineness of 17 "standard dtex" and a total fineness of 3000 "standard dtex" (see, for example, Patent Document 2), and particularly tufted pile fabrics which have high production efficiency, are preferably used for them. In contrast, although the needles of the knitting machines that produce warp knitted pile fabrics and weft knitted pile fabrics are both called "needles," they are significantly more delicate and complex than the needles of tufting machines, and because the arrangement spacing (needle gauge) is fine, thick pile yarns with a total fineness exceeding 1,100 "standard dtex" cannot be used. Instead, thin pile yarns are used, so the fabrics are soft to the touch and are used for bedding and underwear, but are not well suited for carpets.

[0003] Some tufted pile fabrics use a thin base fabric and are used to make simple rugs that can be packed compactly and stored easily (see, for example, Patent Document 3). However, these fabrics are not as soft as weft-knitted pile fabrics, and when the pile layer is folded face-up, cracks form in the pile layer, causing the base fabric at the base of the pile to have an undesirable appearance known as "grinning," which looks just like a row of teeth protruding from the gap between the upper and lower lips (see, for example, Patent Document 4). In particular, automobile foot mats are molded into a three-dimensional shape to fit the vehicle floor frame, and there are many corners where the pile surface cracks and protrudes, and the shadow of the base of the pile is vaguely visible in these cracks, causing the problem of "greening." However, a continuous dyeing method has also been proposed that takes advantage of the "growning" that occurs when the pile surface cracks, by spraying the dye solution down to the base of the pile to give the pile surface a darker color (see, for example, Patent Document 5).

[0004] As shown in Figure 7, the pile surface (12x) of the tufted pile fabric (11) is depicted as looking like a densely packed moss field or a rice field with stumps remaining after harvesting, and on the base fabric (15x), the pile yarn protruding from the pile base (13) continues vertically as backstitches (10) connecting the bases (13x, 13x, 13x, ...), and the space between the left and right backstitches (13x~13x) forms a depression (9) that continues vertically. This backstitch (10) is a natural occurrence in tufted pile fabric (11), but it accounts for approximately 30% of the pile yarn used, and is a factor in increasing the cost of tufted pile fabric (11). As is easily understood from the fact that the sides of tufted pile fabric can be depicted as being like the gaps between lined up wine glasses or a tree-lined avenue covered with branches and leaves, water that spills onto the pile surface collects in the gaps (14x) between the bases of the pile (13x~13x), then passes through the base fabric and wraps around to the backside of the base fabric (15x), where it collects in the depressions (9) between the backstitches (13x~13x).

[0005] However, as shown in FIG. 2, in a pile weft knitting machine, the pile yarn (17) is fed to the needles (23) from a higher position that is spaced apart from the weft yarn (18). The sinker (26) is provided with a weft thread engaging / disengaging portion (24) for supporting the weft thread (18) forming the weft thread sinker loop (19g), and a pile thread engaging / disengaging portion (25) for supporting the pile thread (17) which rises high from the weft thread engaging / disengaging portion (24) and forms the pile thread sinker loop (19g) which becomes the pile (22). The tip of the pile yarn engaging / disengaging portion (25) protrudes in a hook shape in the same direction as the tip of the weft yarn engaging / disengaging portion (24) so ​​that when the sinker (26) is protruded into the gap between adjacent needles (23-23), it enters between the pile yarn (17) and the weft yarn (18), which are fed in two stages, upper and lower. The needle (23) rises higher than the pile yarn (17) fed through the pile yarn engaging portion (25), hooks the pile yarn (17) and the weft yarn (18), and then descends. During the downward movement, the pile yarn (17) is caught in the pile yarn release portion (25), and the weft yarn (18) is caught in the weft yarn release portion (24). As the needle (23) descends further and passes under the old needle loop (20b) formed earlier, the new pile yarn (17) and weft yarn (18) fed from the yarn feeder are hooked around the needle (23) through the old needle loop (20b) and pulled out as a new needle loop (20a). When the needle (23) rises in the next knitting course, the tongue (27) is caught in the new needle loop (20a), the hook of the needle (23) opens, and the knitting process of the next course is resumed.

[0006] Thus, in the weft-knitted pile fabric (16), the pile yarns (17) are knitted together with the weft yarns (18) and form needle loops (20) together with the weft yarns, thereby constituting a part of the base fabric (15). The base fabric is constructed via sinker loops, so that the bases (13, 13) of adjacent piles (22, 22) are bound together by needle loops (20). Therefore, in the weft-knitted pile fabric, gaps (14) resembling a tree-lined avenue do not occur between the bases of the tufted pile fabric (13-13), and the situation in which water that spills onto the pile surface instantly passes through the base fabric and accumulates on the back side of the base fabric is prevented. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Utility Model Publication No. 8-3323 (Example 1) [Patent Document 2] Jpn. Jpn. Published No. 55-47428 [Patent Document 3] Jpn. Jpn. Published No. 60-38714 [Patent Document 4] Special Publication No. 5-55626 [Patent Document 5] Special Publication No. 62-50502 Summary of the Invention [Problem to be solved by the invention]

[0008] However, weft-knitted pile fabrics, particularly those knitted on a circular knitting machine in which needles and sinkers are arranged in a tubular shape, have a unique property of being able to stretch more in both the horizontal direction in which the weft yarns (18) run, and in the vertical direction perpendicular to the horizontal direction, than other pile fabrics, i.e., woven pile fabrics, warp knitted pile fabrics, and tufted pile fabrics. The weft yarn (18) of the weft knitted fabric (16) knitted on a circular knitting machine is fed from a feeder (yarn feeder) in such a way that the weft yarn is wound around the circumference of a cylinder in which needles are arranged in a cylindrical shape during knitting, connecting adjacent needles in a straight line, and the needle loops (20) and sinker loops (19) spread out horizontally to form horizontally long stitches (28) (see Figure 4). However, during the removal process when the yarn is released from the needle and sinker, it is pulled in the axial direction of the cylinder and deformed into vertically elongated stitches (29) (see Figure 5). Then, when the yarn is removed from the weft knitting machine and released from tension, the needle loops (20) and sinker loops (19) are transformed into rounded relaxed stitches (30) for practical use, and are stretched and contracted when pulled vertically and horizontally (see Figure 3).

[0009] If this is the case, then in order to prevent water that has spilled onto the pile surface from instantly penetrating the base fabric, it seemed essential to apply a binder to the base fabric, which would harden the needle loops (20) and sinker loops (19) and maintain them in a rounded state, thereby suppressing the expansion and contraction deformation of the base fabric (15). To achieve this, it is essential to make the weft yarn (18) a multifilament yarn (multiple-fiber yarn) rather than a monofilament yarn, and fill the gaps between the fibers inside the weft yarn with a binder to enlarge and harden the weft yarn, maintain the needle loops (20) and sinker loops (19) in a rounded state, and suppress the expansion and contraction deformation of the base fabric (15).

[0010] In the weft-knitted pile fabric, the pile yarn (17) is knitted together with the weft yarn (18) to form needle loops (20) together with the weft yarn (18), which constitute a part of the base fabric (15), and the sinker loops (20) of the pile yarn are pulled away from the sinker loops (19) of the weft yarn (18) to form the pile (22). In this case, by making the total fineness of the pile yarns (17) thicker, the weight of the pile layer (21) can be increased, and by making the total fineness of the weft yarns (18) thinner, the needle loops (20) can be made finer, the pile (22) can be made denser, the gaps (14) between the pile roots (13-13) can be made finer, the surface area of ​​the fibers in the pile layer (21) can be increased, and water that spills onto the pile surface is absorbed into the pile layer by the action of surface tension and becomes less likely to permeate, and also, since the fibers in the pile layer are in close contact with each other, grinning (exposure) is less likely to occur. Furthermore, in weft-knitted pile fabric, each pile thread is not pinched one by one, and if each weft thread (18) is reinforced with a binder, the needle loops (20) will not be torn off even if the pile threads are pinched one by one and pulled. If this is the case, the fact that the total fineness (thickness) of the weft yarns (18) is smaller (thinner) than the total fineness (thickness) of the pile yarns (17) will not immediately cause any inconvenience, and not only will it have an effect of preventing grinning (exposure), but it will also form needle loops (20) that dig into the base of the pile and bind it strongly, and the needle loops (20) formed by the weft yarns will also become finer, making the back surface of the weft-knitted pile fabric smooth and requiring less binder to be applied to the weft yarns (18) to strengthen it.

[0011] When pulled lengthwise and widthwise, weft-knitted pile fabrics have the unique property of being able to stretch lengthwise and widthwise to a greater extent than woven pile fabrics, warp-knitted pile fabrics, or tufted pile fabrics. If you think about it, when a weft-knitted pile fabric is pulled horizontally, it stretches horizontally because the curved shape of the knitting yarn, which was curved to form needle loops and sinker loops as shown in Figure 3, is changed to a straight shape like the long horizontal sides of horizontally elongated rectangular needle loops and sinker loops as shown in Figure 4, but the knitting yarn itself is not stretched. Conversely, when a weft-knitted pile fabric is pulled vertically, it stretches vertically because the curved shape of the knitting yarn, which was curved to form needle loops and sinker loops as shown in Figure 3, is changed to a straight shape like the isosceles of a vertically elongated isosceles triangle needle loops and sinker loops as shown in Figure 5, but the knitting yarn itself is not stretched, and the original shape can be restored by adjusting the amount of pulling in the vertical and horizontal directions. Perhaps for this reason, even though underwear and socks are ironed to make them look good when displayed in stores, we never hear of anyone ironing underwear or socks, which are washed and used frequently on a daily basis. This is because even if there are some small wrinkles, once worn, the garment becomes knitted (very small), so it fits against the skin and the wrinkles disappear, so you no longer have to worry about them. In this way, in that wrinkles are not a problem, weft-knitted pile fabrics have a remarkable uniqueness that distinguishes them from woven pile fabrics, warp-knitted pile fabrics, and tufted pile fabrics. And because of this peculiarity, it was thought that there would be no particular inconvenience in using a wet heat shrinkable fiber for the weft yarn of the base fabric of a weft-knitted pile fabric in order to make the knitting density finer. The present invention was completed based on these findings, particularly the change from horizontal elongated stitches (28) (Fig. 4) during the knitting process of needle loops and sinker loops to vertical elongated stitches (29) (Fig. 5) when taken out, and the change to relaxed stitches (30) (Fig. 3) when in use, as well as the benefits and disadvantages that arise from these changes, such as localized changes to a ribbed knit structure to prevent the cut opening of the knitted fabric from rolling up, or fulling or resin processing of the cut opening.

[0012] Generally, the mass of the pile yarn (17x) and the weft yarn (18x) is calculated in units of "g (gram)" and expressed in units of "dtex." In general, the mass of the pile layer is calculated based on the unit area of ​​the pile layer (1 m 2 ) and the total mass is calculated as "g / m 2 It is expressed in units of "pile weight", called "pile basis weight", and is widely used in the industry. However, although these units are appropriate for calculating the cost price and unit price of commercially traded textile products such as pile yarn and pile fabric, they are inappropriate for specifying the technical content of textile products. These units of measurement allow one to compare and evaluate the thickness and bulk (volume) of textile products such as pile yarns and pile fabrics that are made from fibers with the same specific gravity, but it is not possible to compare and evaluate the thickness and bulk (volume) of textile products that are made from fibers with different specific gravities. Therefore, in the present invention, (a) When calculating the thickness or bulk (volume) of a fiber or fiber thread expressed in the unit "dtex", the mass of the fiber or fiber thread shall be divided by the specific gravity of the fiber or fiber thread to obtain a standard mass expressed in the unit "g", and the thickness or bulk (volume) of the fiber or fiber thread shall be calculated using this standard mass and expressed in the new unit "standard dtex". (b) Unit: m 2 The unit area of ​​the pile layer is expressed as "1m 2 When calculating the bulk density (volume) of the pile fiber in the pile layer by standardizing the mass of the pile layer, which is expressed in units of "g" per "gram," by the specific gravity of the fiber or fiber yarn, First, (1) the unit area of ​​the pile layer is “1m 2 Unit of "g / 10000cm 2 Calculate the standard total mass per unit area of ​​pile fiber, which is indicated by " Next, (2) divide the standard total mass per unit area by the pile layer thickness expressed in units of "cm" to obtain the standard total mass per unit area. 3 The unit volume of the pile layer is expressed as "10000 cm 3 Unit of "g / 10000cm 3 " to calculate the total mass per unit volume. The unit of total mass of this unit volume is "g / 10000cm 3 " is the 9th volume of 10,000 cm 3 But 10,000 cm 3 =100cm×100cm×1cm=1m 2 × 1cm, so the unit volume total mass is μg / 10000cm 3 Multiplying the specific gravity ρ of the pile layer fibers or fiber threads by the thickness of the pile layer γcm gives μ×ρ×γ(cm×g / m 2 ×cm) = μ × ρ × γ (g / m 2 ) is the pile basis weight μ×ρ(g / m 2 ) and this makes it easy to convert between "total mass per unit volume of the pile layer" and "pile weight per unit area," and also makes it easy to compare the present invention with the prior art.

[0013] However, in order to do so, the unit area of ​​the pile layer (1 m 2 ) requires a large pile fabric capable of sampling a sample corresponding to the size of the yarn, and in some cases, a knitting machine with a different needle gauge, winding device, etc. may be required. Therefore, in the present invention, the sample size of the pile fabric required to calculate the "total mass per unit volume" is reduced, and the unit area of ​​the pile layer is set to 100 cm. 2 (=10cm×10cm=0.01m 2 ) and reduce the unit volume total mass to one percent and use the unit "g / 100cm 3 " is the "standard pile fiber weight." [Means for solving the problem]

[0014] The present invention relates to a weft-knitted pile fabric (16) in which pile yarns (17) are knitted into a weft-knitted base fabric (15) in which a weft yarn (18) is knitted in a plain knit structure, and the pile yarns (17) are integrated with the weft yarn (18) to form needle loops (20) in a plain knit structure, and a sinker loop (19p) overlapping a sinker loop (19g) formed by the weft yarn (18) projects from the back stitch of the needle loop (20) to form a pile (22) whose two roots (13) are surrounded by the needle loop (20); (2)(a) Two piles at each base of two needles surrounded by one needle loop (20) constitute one pile, and the pile is a square of 10 x 10 cm2 in area, with one side 10 cm long in the course direction and one side 10 cm long in the wale direction intersecting at right angles. 2 The pile density (Θ), which is the number of piles per unit area, is 1050 piles / 100cm. 2 That's all. (3) Unit depth (1 cm) and unit area (100 cm 2 ) is 5g / 100cm 3 The first feature of the weft-knitted pile fabric (16) is as described above. The "unit depth of the pile layer (1cm)" mentioned here does not mean that the thickness of the pile layer is 1cm, but rather that the pile layer thickness γ (cm) is divided by the pile layer thickness γ (cm), resulting in a numerical value of "1" or "1cm". Even if the pile layer thickness γ (cm) is a decimal point, it is still "1cm".

[0015] The second feature of the present invention, in addition to the first feature, is Second constituent element (1) The distance (α) between two adjacent piles in the course direction is less than 0.38 cm. Second constituent element (2) The distance (β) between two adjacent piles in the wale direction is less than 0.25 cm. Third component (3) The pile yarn (17) is made of a large number of filaments (fibers), The fourth constituent feature (4) is that the standard fineness of the weft yarn (18) is made finer than the standard fineness of the pile yarn.

[0016] The third feature of the present invention is that, in addition to either of the first or second features described above, the pile yarns (17) are composed mainly of crimped fibers and are bulkier than the weft yarns (18), and the shrinkage rate of the pile fabric (16) in either the course direction or the wale direction is less than 10% when immersed in boiling water at 100°C for 60 minutes.

[0017] A fourth feature of the present invention is that, in addition to any one of the first, second, or third features described above, the pile yarn (17) is a multifilament yarn (multi-fiber yarn) consisting of many filaments (fibers) and having a standard fineness of 200 to 600 (standard dtex), the weft yarn (18) is a multifilament yarn (multi-fiber yarn) having a standard fineness of 100 to 200 (standard dtex), which corresponds to 1 / 2 to 1 / 3 of the standard fineness of the pile yarn, and a binder is applied to the back surface of the pile fabric (16) facing the pile surface (12), and the weft yarn (18) is enlarged by the binder. A fifth feature of the present invention, in addition to the above-mentioned fourth feature, is that a water-repellent material is added to the binder applied to the back surface of the pile fabric (16).

[0018] A sixth feature of the present invention is that, in addition to any one of the first, second, third, fourth, or fifth features, a backing material (8) is laminated on the back surface of the pile fabric opposite the pile surface. The seventh feature of the present invention, in addition to the sixth feature described above, is that the adhesive component (31) interposed between the back surface of the pile fabric facing the pile surface (12) and the backing material (15) is adhered (8) to the weft yarns (18) constituting the base fabric (15) without protruding into the pile layer (21). An eighth feature of the present invention is that, in addition to any one of the first, second, third, fourth, fifth, sixth, and seventh features, the product is three-dimensionally shaped by forging.

[0019] The ninth feature of the present invention is that, in addition to any one of the first, second, third, fourth, fifth, sixth, seventh, and eighth features described above, the present invention is made into a three-dimensional shape that fits the vehicle floor frame and has a flat surface (2) that is recessed and continues from a protruding corner (3), and is used to form the covering of an automobile foot mat (1), a seat rest (4), a back rest (5), a head rest (6), an arm rest (7), an ottoman, or other automobile interior material. The tenth feature of the present invention is, in addition to any one of the first, second, third, fourth, fifth, sixth, seventh, eighth and ninth features above, that the pile spacing in the wale direction (β) is narrower than the pile spacing in the course direction (α) (β<α). The eleventh feature of the present invention is (1) a weft-knitted pile fabric (16) in which pile yarns (17) are knitted into a weft-knitted base fabric (15) in which a weft yarn (18) is knitted in a plain knit structure, and the pile yarns (17) are integrated with the weft yarn (18) to form needle loops (20) in a plain knit structure, and a sinker loop (19p) overlapping a sinker loop (19g) formed by the weft yarn (18) protrudes from the back stitch of the needle loop (20) to form a pile (22) whose two roots (13) are surrounded by the needle loop (20); (2) The base (13) of the pile (22) is not exposed at the protruding corner (3) formed on the pile surface (12). Effect of the Invention

[0020] ≪ 1 EV cars and lightweighting ≫ In order to reduce the power consumption of electric vehicles, there is a demand for lighter automotive interior materials. Indeed, tufted pile fabric (11) is applied to automobile foot mats. The tufted pile fabric (11) is formed by inserting needles carrying pile yarns at their tips into a base fabric (15x), and since strong impact stress is applied during the tufting process, an extremely strong and heavy base fabric (15x) is used. The pile of the tufted pile fabric (11) is U-shaped like a rivet and is stuck into the base fabric (15x) like a stapler, making it easy for it to come out. On the other hand, the base fabric (15x) is also damaged by the pile yarn and needles that are inserted together during tufting, so a backing adhesive that joins the backstitch (10) and the base fabric (15x) and a pressure-bonded vulcanized finish using an unvulcanized rubber sheet about 2 mm thick are essential. In contrast, in the base fabric (15) of the weft knitted pile fabric (16) of the present invention, the weft yarns (18) are knitted integrally with the pile yarns (17) in the process of forming the pile (22), and the pile yarns (17) and needles (23) do not strike the base fabric (15) in the knitting process, and neither the weft yarns (18) nor the pile yarns (17) are damaged. Therefore, there is no problem even if the standard fineness of the weft yarns (18) is made thinner than the standard fineness of the pile yarns. On the contrary, the majority of the base fabric (15) is occupied by needle loops (20) in which the pile yarn (17) and the weft yarn (18) are integrated, and the only part occupied by the weft yarn (18) is the sinker loop (19g) connecting two adjacent needle loops (20-20) in the course direction (see Figure 2), so that the base fabric formed by the weft yarn (18) is essentially nonexistent. And since the pile yarns (17) and the weft yarns (18) are integrated to form the needle loops (20), there is no need to glue the pile (17) to the base fabric (15), and there is no need for a backing adhesive or a vulcanized rubber sheet about 2 mm thick. Therefore, according to the present invention, it is possible to reduce the weight of automobile foot mats and meet the demands of the EV automobile industry.

[0021] ≪ 2 Automotive interior materials and comfort ≫ In the present invention, the "standard pile fiber weight" is 5 g / 100 cm 3 The above is a constituent feature of the present invention. This configuration requirement differs from what is commonly referred to as "pile weight" and does not change in proportion to the pile length or thickness of the pile layer. The "standard pile fiber weight" in this invention is the weight calculated in units of mass "g" divided by the specific gravity of the fiber threads in the pile layer to standardize the weight, and the unit of the weight is expressed as "standard pile fiber weight". 2 ) and does not change in proportion to the pile length or thickness of the pile layer. Therefore, even if the "standard pile fiber weight" is the same, there are various weft-knitted pile fabrics (16) having different pile lengths and pile layer thicknesses, and these pile lengths and pile layer thicknesses are appropriately set depending on the application of the weft-knitted pile fabric (16). Therefore, as shown in Figs. 8 and 9, the uses of the weft-knitted pile fabric (16) of the present invention are not limited to automobile foot mats, but can also be applied to seat rests (4), back rests (5), head rests (6), arm rests (7), ottomans and other automobile interior materials with a pile length of about 4 mm, in the same manner as moquette (pile fabric), to improve the comfort of the vehicle interior.

[0022] ≪ 3 Easy to deform, suitable for shaping, simple mat ≫ The weft-knitted pile fabric (16) of the present invention has a base fabric (15) knitted in a flat knit structure that is flexible and stretchable, allowing the aspect ratio of the stitches to be changed in three-dimensional space without creating wrinkles, such as vertical elongated stitches in the shape of elongated isosceles triangles (Figure 5), horizontal elongated stitches in the shape of elongated rectangles that spread out horizontally (Figure 4), or rounded relaxed stitches (Figure 3). The pile yarn (17) does not constitute the entire base fabric (15); only a portion of the pile yarn constitutes the needle loops (20); the pile yarn does not also constitute the sinker loops (19); it is only the weft yarn (18) that constitutes not only the needle loops (20) but also the sinker loops (19) and forms the entire base fabric (15). The standard fineness of the weft yarn (18) is set to 1 / 2 to 1 / 3 that of the pile yarn (17), so that the stitches can easily be stretched and deformed without wrinkling, and a weft-knitted pile fabric with excellent shaping suitability is obtained, which is suitable for a folding carpet. Furthermore, when the fineness of the weft yarn is made finer than that of the pile yarn, the fineness of the pile yarn can be made relatively thicker, which increases the pile fiber density in the pile layer and suppresses greening, thereby improving the various functions of the weft-knitted pile and weft-knitted pile fabric, such as heat retention, heat insulation, sound absorption, soundproofing, moisture retention, moisture absorption, and adhesive workability.

[0023] ≪ 4. Greening resistance ≫ As described above, since only the weft yarns (18) are deformed and shaped, the aspect of the stitches can be changed without wrinkling, so the weft-knitted pile fabric of the present invention is suitable for forging processing. The pile yarns (17) of the weft-knitted pile fabric (16) are integrated with the weft yarns (18) to form needle loops (20) of a plain knit structure, and also protrude from the back of the needle loops (20) with sinker loops (19p) overlapping with sinker loops (19g) of the weft yarns (18) to form piles (22) whose roots (13) are surrounded by the needle loops (20), and the roots (13) are perpendicular to the base fabric (15). Since the sinker loop (19p) continuing from the needle loop (20) of the pile yarn (17) constituting the pile (22) overlaps the sinker loop (19g) of the weft yarn (18), the needle loop (20) of the pile yarn (17) overlaps the needle loop (20) of the weft yarn (18), so that the needle loop (20) of the weft yarn (18) is hidden under the needle loop (20) of the pile yarn (17) and is unlikely to appear on the pile surface side (12), and the base fabric (15) of the weft yarn (18) is unlikely to be exposed on the pile surface (12) (see Figure 6). As a result, the pile surface side (12) of the base fabric (15) is colored in the color of the needle loops of the pile yarns (17) that overlap the needle loops of the weft yarns (18), and is the same color as the bases (13) of the pile (22). Therefore, even if the pile surface (12) is folded to protrude the needle loops, or even if the pile length is shortened and the pile layer (21) is made thinner, the shadows of the base fabric (15) will not appear conspicuously on the pile surface (12). For this reason, in the small living space of a car, the pile surfaces of the corners (3) of the automobile interior materials such as the foot mat (1), seat rest (4), back rest (5), head rest (6), arm rest (7), ottoman, etc., which are in close proximity and visible up close, are curved, and even if cracks are likely to occur along the ridges of the corners (3), there is no talk of greening (see Figures 8 and 9). If the standard fineness of the weft yarn (18) is set to 100-200 (standard dtex), which corresponds to 1 / 2 to 1 / 3 of the standard fineness of the pile yarn (17) of 200-600 (standard dtex), even if it is possible to push aside the pile layer and identify the pile root (13), it is not possible to find the thin weft yarn (18) underneath the needle loop of the thick pile yarn, so that greening is less likely to occur. To give a supplementary explanation, there is a raised fabric similar to pile fabric. It is made by using a flat fabric such as a plain weave or plain knit as the base fabric (15y), and raking out the fibers exposed on the surface with the hook of a needle cloth or thistle seeds to make it fluffy, and is mainly used for women's clothing (coats) and interior materials. The raised fabric used for interior materials is passed through a shearing to cut off the nap tips (39), and the ground (base fabric 15y) is visible like flannel or raglan with the nap (40) cut short, and raised fabrics that no longer undergo grinning are in a technical category different from that of the present invention and cannot be compared with the present invention.

[0024] ≪ 5. The meaning of “standard pile fiber weight” ≫ The "standard pile fiber weight" (δ) is an important component of the present invention. Regarding this requirement, in the present invention, the unit depth (1 cm) and unit area (100 cm 2 The "standard pile fiber weight" (δ) per 100cm is 5g / 100cm 3 The above is stipulated. This means that the pile layer has a unit depth (1 cm) and a unit area (100 cm 2 ) is the volume of 100 cm 3 5 cm of the three-dimensional space 3 The pile fibers make up the remaining 95cm 3 This means that 95% of the pile layer's volume is occupied by tiny gaps within the pile layer. That is, the "5g / 100cm 3 " means the standard mass of the pile fibers divided by the specific gravity of the pile fibers. Standard mass is “5g / 100cm 3 "The mass of porous materials such as polystyrene foam, polyurethane foam, polyethylene foam, and thermal adhesive fiber-containing fiber laminates, which are used in many fields as cushioning materials, shock-absorbing materials, sound-absorbing and sound-proofing materials, and heat-insulating materials, is generally "5g / 100cm" when divided by their specific gravity. 3 “It will be before and after. Therefore, the weft-knitted pile fabric of the present invention has a surface covered with pile, which feels pleasant to the touch, is highly designable, and can be used as a high-added-value sound-absorbing or sound-proofing material that also serves as a decorative material, heat-retaining or insulating material, cushioning material or shock-absorbing material, architectural interior material, and, because it is stretchable and flexible, it can be used in a wide range of applications, such as blankets, drapes, and cold weather gear.

[0025] ≪ 6. Moisture retention and water resistance ≫ The distance (α) between adjacent needle loops in the course direction is less than 0.38 cm, and the distance (β) between adjacent needle loops in the wale direction is less than 0.25 cm. The area of ​​a square with one side 10 cm long in the course direction and one side 10 cm long in the wale direction intersecting at right angles is 10 × 10 cm. 2 The unit area is calculated by the number of piles in the unit area, and the pile density (Θ) is calculated by 1050 piles / 100 cm. 2 The unit depth (1 cm) and unit area (100 cm 2 ) is 5g / 100cm 3 When the above is done, the pile layer is finely divided by the pile fibers, the surface area of ​​the surrounding sides of the pile fibers that come into contact with the air in the pile layer increases, and the fine gaps between the pile fibers that come into contact with each other in the pile layer increase, so that water that has spilled onto the pile surface (12) is adsorbed into the pile layer as if it were being sucked into the gaps between the fibers by the action of surface tension, and is held in the pile layer just as if it were ink from a felt pen, and does not immediately flow around to the back surface of the weft-knitted pile fabric (16), making it possible to buy some time before wiping up the water that has spilled out. The term "waterproof" in this invention means that water that has spilled down is retained in the pile layer for a short time without penetrating the pile fabric until it is wiped off. It does not mean complete waterproofing like water pillows, ice packs, water bags, etc., but means that the amount of water that accidentally spills down inside a car can be wiped off with tissue paper. This level of waterproofing is achieved by applying a "standard pile fiber weight" of 5g / 100cm to the pile layer. 3 This is because it is ensured by the above. Therefore, the weft-knitted pile fabric of the present invention has high moisture retention and excellent water impermeability, making it suitable not only for automobile foot mats, but also for diapers, sanitary products, and sheets for nursing care and the elderly.

[0026] ≪ 7. Economic Efficiency ≫ There are three basic knitting structures for weft knitted fabrics: tuck knitting structure, purl knitting structure, and plain knitting structure. In the tuck knit structure, ridges are formed in which the purl and face stitches cross in the course direction and continue in the wale direction, and adhesive accumulates in the ridges, increasing the amount of adhesive applied and making it uneconomical. In the pearl knit structure, a single large stitch is generated in which multiple needle loops of multiple courses running back and forth in the wale direction overlap, which becomes a water permeable hole, so a water-impermeable weft-knit pile fabric cannot be obtained. In this regard, the base fabric (15) of the present invention employs a plain knit structure, with pile protruding from the back stitch, and only the front stitch appears on the back surface of the base fabric (15), making the back surface smooth and even. When adhesive is applied to the back surface, no coating spots are formed and only a small amount of adhesive is required, making it economical.

[0027] ≪ 8 Benefits of crimped fibers ≫ Non-shrunk fibers extend straight in the direction of the fiber axis, and in the multifilament yarn made from them, the fibers that come into contact with each other are tightly packed together, just like bundled dried somen noodles, and there is no room for moisture to penetrate. In this regard, crimped fibers extend while bending in the direction of the fiber axis, and the resulting multifilament yarn (multi-fiber thread) has countless fine gaps between the fibers, through which moisture and the like can penetrate, thereby enhancing the effects of the present invention, such as moisture retention, water barrier properties, sound absorption, heat retention, and insulation.

[0028] ≪ 9. Hot water shrinkage rate and heat resistant shape stability ≫ Textile products such as partition curtains, drapes, bed covers, and sheets used in hospitals, nursing homes, and senior citizens' homes must be washed repeatedly, sterilized, and ironed to be constantly kept clean. In this case, if the textile product is washed in boiling water at 100°C, no special sterilization treatment is required, and the textile product does not shrink in hot water, so the shape and dimensions of the textile product are maintained constant. Moreover, since these textile products are weft knitted fabrics that are originally stretchable and do not require ironing, the burden and effort of caregivers who handle these textile products is reduced. In other words, during the use of the weft-knitted pile fabric of the present invention, there may be cases where heat resistance and shape stability, that is, resistance to deformation due to heat, is required for the weft-knitted pile fabric (16). The hot water shrinkage rate (ε) of a weft yarn unwound from a weft-knitted pile fabric when it is immersed in boiling water at 100° C. for 60 minutes was measured as shown in FIG. 10. Zeolites (33) were laid on the bottom plate (32) of a heating container, a bottom blind (34) was placed on top of that, a mesh case (mesh basket) (35) containing the weft yarn (a) was placed on top of that, a presser blind (36) was placed on top of that, and gravel (37) was lightly laid on top of that. The weft thread (b) is then stuffed, poured over with boiling water at 100°C, and boiled for 60 minutes, after which the weft thread (b) is taken out and dried. The difference (ΔL) between the length (La) of the weft thread (a) before boiling and the length (Lb) of the weft thread (b) after boiling is divided by the length (La) of the weft thread (a) before boiling to obtain the quotient (ΔL / La), which is then multiplied by 100 to obtain a calculated value expressed as a percentage (%) {(ΔL / La) x 100} {ε = (ΔL / La) x 100} (%). In this case, the length (La) of the weft thread (a) before boiling and the length (Lb) of the weft thread (b) after boiling are measured by fixing one end of each of the weft threads (a) before boiling and (b) after boiling to a horizontally supported beam and hanging them, and attaching light weights to their lower ends so that the slack is removed from the weft threads and they are aligned in a straight line. As long as the mass of the attached weights is the same, their shape and material do not matter. A light fish clip or a light office paper clip are suitable for use as weights.

[0029] ≪ 10. Hot water shrinkage rate and complementary requirements of the present invention ≫ In order to make the shrinkage percentage of the weft-knitted pile fabric (16) of the present invention in either the course direction or the wale direction of the pile fabric (16) less than 10% when immersed in boiling water at 100°C for 60 minutes, it is sufficient to make the shrinkage percentage of the weft yarn (18) woven into the weft-knitted pile fabric less than 10% when immersed in boiling water at 100°C for 60 minutes. Among fibers, there are fibers that shrink easily and fibers that do not shrink easily, and among the fibers that shrink easily, there are fibers that shrink when exposed to water and fibers that shrink when exposed to heat. Generally, fibers that shrink when exposed to water are called water-shrinkable fibers, and fibers that shrink when exposed to heat are called heat-shrinkable fibers. However, if it shrinks when it comes into contact with water, it will shrink when it comes into contact with boiling water, and if it shrinks when it comes into contact with heat, it will shrink when it comes into contact with boiling water. Thus, if both water-shrinkable fibers and heat-shrinkable fibers shrink when they come into contact with boiling water, they can be collectively called hot-water-shrinkable fibers. However, this does not mean that fibers that are difficult to shrink in water and fibers that are difficult to shrink in heat can be collectively called non-hot water shrinkable fibers and distinguished from hot water shrinkable fibers. This is because plant-based cellulose fibers such as cotton, flax, linen, jute, and ramie do not shrink instantly when they come into contact with hot water, but if they are immersed in even room temperature water for a long period of time, the fiber cells will swell and shorten in length, i.e., they will shrink. Although they do not shrink instantly when exposed to hot water, even ordinary thermoplastic synthetic fibers that have been stretched and are in a crystalline region where the polymer arrangement structure is aligned will gradually shrink if immersed in boiling water for a long period of time, as the shrinkage stress accumulated inside the fiber during the stretching process gradually becomes apparent. On the other hand, even if a fiber is hot-water-shrinkable, once it comes into contact with hot water and shrinks due to the manifestation of shrinkage stress, it loses its hot-water-shrinkage function and becomes a non-hot-water-shrinkable fiber. When immersed in boiling water at 100°C for 60 minutes, the shrinkage rate is less than 10%, and the fiber no longer falls under the category of a hot-water-shrinkable fiber. Therefore, in the present invention, the weft yarn (18) having a shrinkage rate of less than 10% means a yarn having some hot water shrinkage function, regardless of whether it is collectively called hot water shrinkable fiber or not, and which is recognized to have a hot water shrinkage rate of less than 10% when removed from the base fabric (15) of the weft knitted pile fabric (16) and immersed in boiling water at 100°C for 60 minutes. The reason why the shrinkage rate of the weft yarn after immersion in boiling water at 100°C for 60 minutes is specified to be less than 10% in the present invention is that even if the first constituent requirement (1) regarding the pile spacing (α) and spacing (β), the second constituent requirement (2) regarding the pile density, and the third constituent requirement (3) regarding the "standard pile fiber weight" of the present invention cannot be satisfied depending on the specifications and arrangement interval (gauge) of the needles and sinkers of the weft knitting machine, the specifications of the knitted fabric winding device and others, the specifications of the pile yarn and weft yarn material and twist number, and the amount of yarn supply tension of the pile yarn and weft yarn, when the knitted fabric is passed through boiling water at 100°C, the sinker loops (19) and needle loops (20) will shrink, satisfying these constituent requirements, and the weft-knitted pile fabric (16) of the present invention can be obtained. Therefore, specifying the shrinkage rate of the weft yarn after immersion in boiling water at 100° C. for 60 minutes to be less than 10% should be said to be a complementary constituent feature of the present invention, in the sense that it makes the impossible possible. This is because many thermoplastic synthetic fibers have latent heat shrinkage stress generated during the drawing process, and even in general synthetic fibers that are not specifically called "heat shrinkable," this shrinkage stress becomes apparent when the fibers are heated and relaxed. For example, there is variation depending on the fiber manufacturer and specifications, but the heat shrinkage rate of polypropylene fiber is 7 to 14%, that of nylon fiber is 9 to 14%, and that of polyester fiber is around 7%.

[0030] ≪ 11 Shrinkage reduction method and process control ≫ The weft yarn (18) having a shrinkage rate of less than 10% is a yarn that is recognized to have a hot water shrinkage rate of less than 10% when removed from the base fabric (15) of the weft-knitted pile fabric (16) and immersed in boiling water at 100°C for 60 minutes. The shrinkage rate of the raw yarn before being knitted into the base fabric (15) of the weft-knitted pile fabric (16) may not be less than 10% but may be 10% or more. Furthermore, the shrinkage rate of the raw yarn may be 10% or more when it is knitted into the base fabric (15) of the weft-knitted pile fabric (16) and enclosed in the stitches. This is because (1) even if the fiber is hot water shrinkable, if it is immersed in boiling water at 100°C for 60 minutes, its shrinkage rate will be less than 10%, (2) even if the raw yarn has a shrinkage rate of 10% or more before it is knitted into a weft-knitted pile fabric, if it is immersed in boiling water at 100°C for 60 minutes, its shrinkage rate will be less than 10%, and (3) even if the weft yarn has been knitted into a weft-knitted pile fabric and has a shrinkage rate of 10% or more when trapped in the stitches, its shrinkage rate will be less than 10% if it is immersed in boiling water at 100°C for 60 minutes. In other words, any hot-water-shrinkable fiber having some hot-water-shrinking function can have its shrinkage rate adjusted to less than 10% by immersing it in boiling water at 100°C for 60 minutes. This makes it unnecessary to individually control the quality of the weft yarn or weft-knitted pile fabric according to differences in shrinkage rate, and facilitates process control.

[0031] ≪ 12 Shrinkage reduction method and economic efficiency ≫ If this is the case, then any weft-knitted pile fabric having a weft yarn containing hot-water-shrinkable fiber having some hot-water shrinkage function will have a shrinkage rate of less than 10% if it is immersed in boiling water at 100°C for 60 minutes. At that time, the weft-knitted pile fabric itself shrinks according to the shrinkage rate of the weft yarn, and the pile spacing in the course direction (α) and the pile spacing in the wale direction (β) also shrink. As a result, the number of pile threads per unit area increases, resulting in a high-quality weft-knitted pile fabric with a dense pile density. Therefore, in the present invention, it is not necessarily necessary to use an expensive so-called fine gauge circular knitting machine which has a precise needle spacing (needle gauge) corresponding to the pile spacing (α) in the course direction of the high-quality weft-knitted pile fabric. It is possible to obtain a high-quality weft-knitted pile fabric even using a conventional circular knitting machine with a coarse needle gauge, making it possible to carry out the present invention economically.

[0032] ≪ 13. Shrinkage reduction treatment requirements ≫ Although any weft-knitted pile fabric incorporating a weft yarn containing hot-water-shrinkable fiber having some hot-water-shrinkage function will have a shrinkage rate of less than 10% if the fabric is immersed in boiling water at 100°C for 60 minutes, this does not necessarily mean that any weft-knitted pile fabric incorporating a weft yarn containing hot-water-shrinkable fiber having some hot-water-shrinkage function must be immersed in boiling water at 100°C for 60 minutes in order to reduce the shrinkage rate of the weft yarn to less than 10%. This is because when hot-water-shrinkable fibers with a melting point of less than 100°C are immersed in boiling water at 100°C, they melt, losing the crystalline structure of the fiber polymer and turning into a resin, no longer retaining their fiber form. Therefore, in order to ascertain whether a weft yarn containing a hot-water-shrinkable fiber having some hot-water-shrinking function that is woven into a weft-knitted pile fabric has a shrinkage rate of less than 10% when immersed in boiling water at 100°C for 60 minutes, it is not necessarily necessary to immerse the weft yarn in boiling water at 100°C for 60 minutes. If the melting point of the hot-water-shrinkable fiber having some hot-water-shrinking function is less than 100°C, it is necessary to ascertain whether the shrinkage rate of the fiber is reduced to 10% in hot water below its melting point. Therefore, rather than saying that "the pile fabric (16) has a shrinkage rate of less than 10% in either the course direction or the wale direction when immersed in boiling water at 100°C for 60 minutes," it should be said that "the pile fabric (16) has a shrinkage rate of less than 10% in either the course direction or the wale direction when immersed in boiling water at 100°C for 60 minutes, in a weft-knit pile fabric woven with a weft yarn containing a high-melting-point hot-water-shrinkable fiber having some hot-water-shrinkability with a melting point of 100°C or higher, or a non-thermofusible hot-water-shrinkable fiber having some hot-water-shrinkability with no melting point, or a weft yarn containing a low-melting-point hot-water-shrinkable fiber having some hot-water-shrinkability with a melting point of less than 100°C ( However, in the case of weft-knitted pile fabrics in which a weft yarn containing a low-melting-point hot-water-shrinkable fiber is woven, it should be confirmed whether or not the shrinkage rate of the fiber is reduced to 10% in hot water below its melting point.

[0033] ≪ 14 Avoidance of edge warping ≫ As described above, when the fineness of the weft yarn is made finer than that of the pile yarn, the stitches of the base fabric (15) are easily stretched and deformed, and the weft-knitted pile fabric is stretchable in three-dimensional space and has excellent shaping suitability, making it suitable for a foldable carpet. Furthermore, the fineness of the pile yarn can be made relatively thicker, and the pile fiber density in the pile layer of the weft-knitted pile fabric is increased, suppressing greening and improving various functions such as heat retention, insulation, sound absorption, soundproofing, moisture retention, moisture absorption, and adhesive workability. However, as the weft yarn becomes thinner, the edges of the weft-knitted pile fabric tend to roll up or curl upwards due to the flexibility of the weft yarn. However, if a binder is applied to the back surface of the pile fabric (16) that faces the pile surface (12), the weft yarns are wrapped in a coating of the binder, which swells and strengthens them, preventing curling and warping at the edges.

[0034] ≪ 15 Promoting water-blocking effect ≫ In this case, if a water-repellent material is added to the binder, water that spills onto the pile surface and soaks into the pile layer will be repelled by the water-repellent material and will not penetrate to the back surface of the pile layer, further enhancing the water-blocking effect of the pile layer.

[0035] ≪ 16 Uses of backing materials and weft-knitted pile fabrics ≫ Complete water impermeability is achieved by laminating a backing material (8) to the reverse side of the weft-knit pile fabric that faces the pile surface. The backing material (8) may be paper, elastic mortar board, synthetic resin plate, plastic foam plate, fabric, needle punched felt, hot melt resin sheet, hot melt resin powder, flowable resin composition, or the like. Elastic mortar boards, synthetic resin plates, plastic foam plates, paper, fabrics and needle punched felts are bonded to the backside of the weft knit pile fabric via an adhesive. The hot melt resin sheet and the hot melt resin powder are laminated on the back surface of the weft knitted pile fabric and heat fused thereto. Hot melt resin powder can be layered and fused directly onto the backside of the weft knit pile fabric by the curtain flow coating method, in which the powder is extruded in the form of a hot melt film from a T-die extruder. The flowable resin composition is applied to the back surface of the weft-knitted pile fabric, heat-fused, and cooled to solidify. Depending on the properties and thickness of the backing material (8), the weft-knitted pile fabric is used for interior materials such as ceiling coverings, wall coverings, and facings when the backing material (8) is paper, fabric, hot-melt resin sheet, or synthetic resin flat plate or plastic foam flat plate with a layer thickness of about 1 mm, and for building materials such as carpets, tile carpets, flooring, ceiling materials, wall coverings, and decorative panels when the backing material (8) is needle-punched felt, elastic mortar board, synthetic resin flat plate, plastic foam flat plate, or hot-melt resin powder or flowable resin composition with a layer thickness of about 2 to 4 mm.

[0036] ≪ 17 Disposal and recycling ≫ If the adhesive component (31) interposed between the back surface of the pile fabric facing the pile surface (12) and the backing material (8) is adhered to the weft yarns (18) constituting the base fabric (15) without protruding into the pile layer (21), the adhesive component layer (31) will be thin and will peel off between the pile fabric and the backing material (8) at the time of disposal, making it easy to separate and recover, which is also convenient in terms of recycling.

[0037] ≪ 18 Fit Forging ≫ As described above, the base fabric (15) is a weft-knitted fabric with a flat knit structure that is flexible and stretchable, and the weft yarns (18) are thinner and more stretchable than the pile yarns. Moreover, the sinker loops of the weft yarns form a plain knit structure of auxiliary yarns that are overlapped on the sinker loops of the pile yarns and appear on the back surface of the weft-knitted pile fabric, and the unvulcanized rubber sheet that serves as the backing material (8) on the back surface is integrated with the pile layer via the sinker loops of the weft yarns. The integrated weft-knitted pile fabric and unvulcanized rubber sheet are then sandwiched between a mold and heated to vulcanize it, resulting in a weft-knitted pile fabric backed by a rubber sheet with a sharp, three-dimensional shape that corresponds to the shape of the mold. Therefore, according to the present invention, it is possible to obtain a weft-knitted pile fabric which is suitable for use as a three-dimensionally shaped foot mat for use in a car interior, engine room, etc., and which can be fitted to a base having a complex structure and has sound-absorbing, vibration-damping and soundproofing effects. [Brief description of the drawings]

[0038] [Figure 1] FIG. 2 is an enlarged perspective view of a part of the weft-knitted pile fabric of the present invention; [Diagram 2] FIG. 2 is a perspective view of a main part of a pile weft knitting machine. [Diagram 3] FIG. [Figure 4] FIG. [Diagram 5] FIG. [Figure 6] FIG. 2 is a perspective view of the joining portion of the weft-knitted pile fabric of the present invention to the backing material. [Figure 7] FIG. 2 is a partial perspective view of the back surface of the tufted pile fabric. [Figure 8] 1 is a perspective view of an automobile foot mat made of the weft-knitted pile fabric of the present invention; [Figure 9] 1 is a perspective view of an automobile interior material made of the weft-knitted pile fabric of the present invention. [Figure 10] FIG. 2 is a perspective view of a boiling water immersion treatment device. [Figure 11] FIG. 2 is a perspective view comparing the main parts of a pile weft knitting machine and a tufting machine. [Figure 12] FIG. 2 is an enlarged cross-sectional view of a portion of the brushed fabric for reference. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] The primary objective of the present invention is to eliminate the problem of greening, which makes the base of the pile visible through the fabric, and to improve the water impermeability of the pile layer so that spilled liquid is less likely to permeate through it. The secondary objective is to achieve these objectives by increasing the pile density, thereby improving the desired functionality of the pile layer, such as heat retention, insulation, sound absorption, soundproofing, moisture retention, and moisture absorption. To achieve these objectives, the following embodiments are recommended.

[0040] <Embodiment 1> (1) Number of piles in the course direction If the pile spacing (α) in the course direction is 0.38 cm, then the number of piles per 10 cm width in the course direction will be 26, calculated by dividing the width of 10 cm by the pile spacing (α) of 0.38 cm (10 / α). (2) Number of piles in the wale direction If the pile spacing (β) in the wale direction is 0.25 cm, then the number of pile stalks per 10 cm in the wale direction will be 40 stalks, calculated by dividing the width of 10 cm by the pile spacing (β) of 0.25 cm (10 / β). (3) Pile density (Θ) The pile density per unit area (Θ) is calculated as the product of the quotients (10 / α) and (10 / β), i.e., 1052 (pile / 100 cm2). 2 ) and (4) "Standard pile fiber weight" (δ) The unit depth (1 cm) of the pile layer and the "standard pile fiber weight" (δ) per unit area are 5 g / 100 cm 3 Let us assume that. However, in order to improve the grinning resistance and water impermeability of weft-knitted pile fabric, it is desirable to make the pile density finer and increase the "standard pile fiber weight" of the pile layer. Also, the finer the pile density and the higher the "standard pile fiber weight" of the pile layer, the more improved the heat retention, insulation, and other functions will be.

[0041] Therefore, preferably, <<Embodiment 2>> (1) Number of piles in the course direction If the pile spacing (α) in the course direction is 0.28 cm, then the number of piles per 10 cm width in the course direction will be 36, calculated by dividing the width of 10 cm by the pile spacing (α) of 0.28 cm (10 / α). (2) Number of piles in the wale direction If the pile spacing (β) in the wale direction is 0.19 cm, then the number of pile pieces per 10 cm in the wale direction will be 53 pieces, calculated by dividing the width of 10 cm by the pile spacing (β) of 0.19 cm (10 / β). (3) Pile density (Θ) The pile density per unit area (Θ) is calculated as the product of the quotients (10 / α) and (10 / β), {100 / (α×β)}, or 1880 piles / 100 cm 2 ) and (4) "Standard pile fiber weight" (δ) The unit depth (1 cm) of the pile layer and the "standard pile fiber basis weight" (δ) per unit area are the same as the "standard pile fiber basis weight" of the above-mentioned embodiment 1, which is 5 g / 100 cm 3 8.9g / 100cm 3 It is calculated as follows.

[0042] More preferably, <Embodiment 3> (1) Number of piles in the course direction If the pile spacing (α) in the course direction is 0.25 cm, then the number of piles per 10 cm width in the course direction will be 40, calculated by dividing the 10 cm width by the pile spacing (α) of 0.25 cm (10 / α). (2) Number of piles in the wale direction If the pile spacing (β) in the wale direction is 0.16 cm, then the number of pile pieces per 10 cm in the wale direction will be 62 pieces, calculated by dividing the width of 10 cm by the pile spacing (β) of 0.16 cm (10 / β). (3) Pile density (Θ) The pile density per unit area (Θ) is calculated as the product of the quotients (10 / α) and (10 / β), i.e., 2500 piles / 100 cm 2 ) and (4) "Standard pile fiber weight" (δ) The unit depth (1 cm) of the pile layer and the "standard pile fiber basis weight" (δ) per unit area are the same as the "standard pile fiber basis weight" of the above-mentioned embodiment 1, which is 5 g / 100 cm 3 11.9g / 100cm 3 It is calculated as follows.

[0043] More preferably, <<Embodiment 4>> (1) Number of piles in the course direction If the pile spacing (α) in the course direction is 0.23 cm, then the number of piles per 10 cm width in the course direction will be 42, calculated by dividing the 10 cm width by the pile spacing (α) of 0.23 cm (10 / α). (2) Number of piles in the wale direction If the pile spacing (β) in the wale direction is 0.14 cm, then the number of pile pieces per 10 cm in the wale direction will be 71 pieces, calculated by dividing the width of 10 cm by the pile spacing (β) of 0.14 cm (10 / β). (3) Pile density (Θ) The pile density per unit area (Θ) is calculated as the product of the quotients (10 / α) and (10 / β), {100 / (α×β)}. 2 ) and (4) "Standard pile fiber weight" (δ) The unit depth (1 cm) of the pile layer and the "standard pile fiber basis weight" (δ) per unit area are the same as the "standard pile fiber basis weight" of the above-mentioned embodiment 1, which is 5 g / 100 cm 3 14.8g / 100cm 3 It is calculated as follows.

[0044] More preferably, <Embodiment 5> (1) Number of piles in the course direction If the pile spacing (α) in the course direction is 0.21 cm, then the number of piles per 10 cm width in the course direction will be 48, calculated by dividing the 10 cm width by the pile spacing (α) of 0.21 cm (10 / α). (2) Number of piles in the wale direction If the pile spacing (β) in the wale direction is 0.14 cm, then the number of pile pieces per 10 cm in the wale direction will be 71 pieces, calculated by dividing the width of 10 cm by the pile spacing (β) of 0.14 cm (10 / β). (3) Pile density (Θ) The pile density per unit area (Θ) is calculated as the product of the quotients (10 / α) and (10 / β), {100 / (α×β)}, or 3401 (pile / 100cm 2 ) and (4) "Standard pile fiber weight" (δ) The unit depth (1 cm) of the pile layer and the "standard pile fiber basis weight" (δ) per unit area are the same as the "standard pile fiber basis weight" of the above-mentioned embodiment 1, which is 5 g / 100 cm 3 16.2g / 100cm 3 It is calculated as follows. With regard to the standard fineness of the pile yarn and the standard fineness of the weft yarn, it is preferable that the pile yarn be a multifilament yarn (multi-fiber yarn) consisting of many fibers and have a standard fineness of 200 to 600 standard dtex, and the weft yarn be a multifilament yarn (multi-fiber yarn) having a standard fineness of 100 to 200 standard dtex, which corresponds to 1 / 2 to 1 / 3 of the standard fineness of the pile yarn.

[0045] Regarding the aspect ratio (κ=100β / α;%) of the pile spacing in the wale direction (β) to the pile spacing in the course direction (α), in embodiment 1 κ1 = 66%, in embodiment 2 κ2 = 68.0%, in embodiment 3 κ3 = 64.0%, in embodiment 4 κ4 = 61.0%, and in embodiment 5 κ5 = 67.0%, resulting in an overall κ = 65.2%. In other words, the pile spacing in the course direction (α) is not equal to the pile spacing in the wale direction (β), and the pile spacing in the wale direction (β) is narrower than the pile spacing in the course direction (α). The reason for this is rather obvious given the structure and physical properties of the flat knit fabric of the stretchable base fabric (15).

[0046] In view of these embodiments, the present invention provides (1)(a) The number of piles per 10 cm width in the course direction, Na (pieces), which is calculated by dividing 10 cm width in the course direction by the pile spacing in the course direction (α) (10 / α); (b) The product of 10 cm of wale length divided by the pile spacing in the wale direction (β), (10 / β), and the number of piles per 10 cm of wale length (Nb), (c) the unit area of ​​the pile surface (10 cm x 10 cm = 100 cm 2 The pile density (Θ) per 100 cm is 1050 pieces / 100 cm 2 That's all. (2) The unit depth of the pile layer (1 cm) and the unit area (100 cm 2 ) and volume 100cm 3 The "standard pile fiber weight" (δ) in the three-dimensional space of the pile layer defined as a rectangular parallelepiped is 5g / 100cm 3 The above can be identified as the weft-knitted pile fabric (16).

[0047] By narrowing the pile spacing in the course direction (α) and the pile spacing in the wale direction (β) in this way, the pile density (Θ) becomes denser and the “standard pile fiber weight” (δ) of the pile layer increases, ensuring the greening resistance and water impermeability of the weft-knitted pile fabric (16). However, when a plain knit fabric is said to be stretchable, it does not mean that the fabric will naturally set while stretched or naturally set while shrunken. Therefore, it means that if tension is applied in either the course direction or the wale direction, the other will temporarily shrink, and it does not mean that the number of stitches per unit area, or in the case of a weft-knitted pile fabric, the pile density, will increase or decrease. More specifically, as explained with reference to Figures 3, 4 and 6, the increase or decrease in the pile spacing in the course direction (α) and the pile spacing in the wale direction (β) referred to in this invention refers to the dimensional change that occurs when the three-dimensional shape of the stitches of the plain knit structure plastically deforms beyond its elastic limit, resulting in permanent distortion, and does not mean that the dimensional change occurs within the elastic limit, i.e., the so-called "free stretch".

[0048] This is because it is generally said that a knitted fabric with a flat knit structure is easier to stretch in the course direction (width direction) than in the wale direction (length direction). Indeed, as shown in Figure 5, the stitches of the weft knitted fabric are pulled in the wale direction (longitudinal direction) during the knitting process when it is pulled out of the weft knitting machine, and are deformed into vertically elongated vertical stitches (29). However, as shown in Figure 4, during the heating and drying process in the post-processing steps such as dyeing finishing after it is removed from the weft knitting machine, the stitches are tensioned in the course direction (width direction) by the tenter pins, and are deformed from the vertical stitches (29) to horizontal stitches (28), and are set in that state. When the horizontal stitches (28) are removed from the heat drying process for dyeing and finishing, etc. and released from tension, they become rounded, relaxed stitches (30) as shown in Figure 3. However, the shape of the horizontal stitches formed in the heat drying process for dyeing and finishing, etc., remains as a quality characteristic of the flat knit structure, allowing the fabric to stretch freely, and the length-to-width dimensional ratio of the horizontal stitches and the ratio of the pile spacing in the wale direction (β) to the pile spacing in the course direction (α) (κ = 100β / α; %) remain, which characterizes the present invention. It can therefore be said that a notable feature of the present invention is that the wale-wise pile spacing (β) is narrower than the course-wise pile spacing (α). For this reason, it is recommended to use hot-water shrinkable fibers for the weft yarn as a means for allowing free plastic changes in the three-dimensional shape of the stitches.

[0049] A flat knitted fabric cannot be obtained by a warp knitting machine. Even if a flat knitted fabric is applied to a tufting machine, the fabric will stretch and sway, making it impossible to implant pile. This means that the so-called "non-standardized conventional weight divided by fiber density" for bonding to the backstitch side of tufted pile fabric as a secondary base fabric is 20 g / m 2 The same is true when attempting to apply a nonwoven fabric of this order. Therefore, the so-called "non-standardized conventional weight divided by fiber density" is 80 g / m 2 This means that we are trying to use a nonwoven fabric of this level as the primary base fabric, but nonwoven fabrics of this level are widely used as primary base fabrics, and it is not possible to obtain a grinning-resistant pile fabric that is suitable for shaping processing. This requires a tufted machine with a needle gauge of less than 25.4÷11 (=1 / 11 inch ≒ 2.3) mm, but the problem is the needle. This is because it is not as simple as simply making the needle thinner to match the needle gauge. In this regard, in the tufting method in which needles are inserted into the base fabric, i.e., the needle insertion method, there is a risk that the needles will be subjected to compressive stress and buckle and break, but in the knitting method in which the pile yarn which is integrated with the weft yarn and is part of the base fabric is pulled out, i.e., the needle withdrawal method, the needles are not subjected to compressive stress and there is no risk of buckling and breakage. Therefore, it is essential to obtain thin needles according to the needle gauge as needed and knit the weft-knitted pile fabric (16).

[0050] The differences and advantages and disadvantages between the needle drawing method (knitting method) and the needle insertion method (tufting method) become clear when comparing the pile formation mechanisms of a weft knitting machine shown in Figure 11(a) and a tufting machine shown in Figure 11(b). That is, in the weft knitting machine shown in FIG. 11(a), adjacent needles 23a, 23b are driven individually in the up-down direction, and the sinkers 26a, 26b are driven individually in the front-to-back direction, so that adjacent piles 22a, 22b are not entangled, and it is relatively easy to narrow the spacing (α) between the adjacent needles 23a, 23b and sinkers 26a, 26b. The needle (23) first rises high and then, as it descends, hooks the pile yarn (17) and the weft yarn (18). As the needle (23) descends further and passes under the old needle loop (20b) formed earlier, the pile yarn (17) and the weft yarn (18) come out of the old needle loop (20b) and become a new needle loop (20a), which is then pulled out. The old needle loop (20b) is then released from the needle (23) and becomes part of the base fabric (15).

[0051] In contrast, in a tufting machine, as shown in FIG. 11(b), adjacent needles (23xa, 23xb) in the width direction of the machine are aligned in a straight line on a needle bar (38) and protrude downward. Together with the pile yarn (17x) carried at their lower ends, each needle is inserted into the base fabric (15x) to form piles (22xa, 22xa'). Therefore, in the process of forming the pile, the needles (23xa·23xb) are configured to be thick so as not to buckle against the impact resistance from the base fabric (15x). If this happens, the base fabric (15x) will easily crack in the width direction of the machine during the pile formation process. Therefore, in a tufted machine, the spacing (αx) between adjacent piles (22xa·22xb) in the machine width direction cannot be narrowed. Moreover, in the tufting machine, it is not possible to narrow the interval (βx) between the piles (22xc) and (22xd) which are successively tufted in the moving direction of the base fabric (15x). This is because, if the interval (βx) between the piles (22xc) and (22xd) becomes too narrow, as shown in Figure 11(b), the pile (22xd) to be sewn last will be pushed down by the previously sewn pile (22xc) toward the tufting point (P) where the next pile will be sewn, and the needle (23xa) will pierce the fallen pile (22xc'), creating a so-called chain stitch in which the previous and following piles (22xc and 22xd) are connected in a chain shape, making tufting impossible. Therefore, depending on the tufting machine, the "standard pile fiber weight" (δ) is 5g / 100cm 3 It will be impossible to obtain a dense pile fabric having a larger density.

[0052] In this regard, in the weft knitting machine, a part of the base fabric (15) and a new needle loop (20a) are formed simultaneously, and during the formation process, the needle (23) does not strike either the base fabric (15) or the new or old needle loop (20a, 20b). Therefore, their movement is not hindered and therefore the needle (23) will not buckle. Therefore, even if the needles (23) are made thinner and the interval (α) between two adjacent needles (23) in the course direction is made smaller, those two needles (23) do not interfere with each other in the process of forming the needle loop (20). The new needle loop (20a) passes through the previously formed old needle loop (20b) together with the needle (23) and is formed before and after the old needle loop (20b). There is no obstacle between the two adjacent needle loops (20, 20) that separates the new and old needle loops (20, 20). The interval (β) between them is made as close as possible to the thickness of the pile yarn (17). Thus, the interval (β) between two adjacent pile threads in the wale direction is narrowed to a distance corresponding to the thickness of the pile yarn. The number of pile threads intervening within a unit area of ​​the pile surface (12) is reduced to 1050 threads / 100 cm. 2 The pile layer has a standard pile fiber weight (δ) of 5g / 100cm. 3 It is possible to achieve the above.

[0053] In a plain knit structure, all needle loops and sinker loops appear on either the front or back side, and on the other side, the continuous portion between the needle loops and sinker loops appears in an "U" shape.The stitches with the continuous portion appearing in an "U" shape are called "front stitches," and the stitches on the opposite side are called "back stitches." 1, 2, 3, 4 and 5 are perspective views of the back stitch side of a plain knit structure.

[0054] The binder applied to the back surface of the pile fabric may be starch or other sugars, water-soluble resins such as sodium alginate and sodium carboxyvinyl alcohol, thermoplastic resins such as vinyl acetate resin, ethylene vinyl acetate resin and vinyl chloride resin, thermosetting resins such as phenol resin, urea resin and melamine resin, or inorganic adhesives such as bentonite, clay, gypsum and cement. Binders soluble in inorganic solvents including water or organic solvents are made into emulsions or dispersions containing the solvent, and are applied by scattering as powder and then adding a solvent, or by laminating and welding as films. The binder may contain fillers such as calcium carbonate, titanium oxide, sodium hydroxide, and micro glass beads, as well as flame retardants and pigments.

[0055] For pile fabrics that are to be forged, the binder may be prepared without interfering with the forging process and may be applied before or after forging depending on the degree of shaping. The backing material (8) to be attached to the back of the pile fabric facing the pile surface (12) is made of a polyvinyl chloride resin sheet, a foamed polyurethane resin sheet, a needle-punched felt made of thermoplastic synthetic fiber, or other thick nonwoven fabric, and backing paper is used for pile fabrics used on ceilings and walls.

[0056] In particular, for the backing material (8) to be bonded to the back side of the pile fabric used for automobile foot mats, it is recommended to apply a needle-punched felt, which contains thick thermoplastic synthetic fibers having a fineness of 10 standard dtex or more and has been singed to melt the fibers and form a functional molten mass with a surface fastener male hook, toward the outside. [Industrial Applicability]

[0057] The weft-knitted pile fabric (16) of the present invention is not only used for automobile interior accessories such as foot mats (1), seat rests (4), back rests (5), head rests (6), arm rests (7), and ottomans, which are easily touched by skin in a small living space and are seen up close for a long time, but also for floor coverings such as the above-mentioned folding rugs, carpets, action rugs, electric heating carpet covers, kotatsu mats, entrance mats, bathroom mats, dust control mats, etc., the standard mass of which is generally close to the "standard pile fiber weight" of the pile layer of the weft-knitted pile fabric (16) of the present invention, is 5g / 100cm. 3 In that it is a porous structure on the front and back, it has the same physical properties and quality characteristics as the weft-knitted pile fabric (16) of the present invention, such as sound absorption, soundproofing, heat retention, insulation, cushioning, and shock absorption, and can be used as a high-added-value alternative to porous materials such as expanded polystyrene, expanded polyurethane, expanded polyethylene, and thermally fusible fiber-containing fiber laminates. It can also be used for interior construction materials, such as blankets, quilts, bed covers, sheets, and other bedding, and cold weather gear, as it is flexible and stretchable. Its uses are diverse, and it will greatly contribute to the development of the industry of the present invention. [Explanation of symbols]

[0058] 1: Foot mat 2:Flat surface 3: Corner 4: Seat rest 5: Backrest 6: Headrest 7: Armrest 8: Backing 9: Hollow 10: Backstitch 11: Tufted pile fabric 12: Pile surface 13: Base 14: Gap 15: Base fabric 16: Weft-knit pile fabric 17: Pile yarn 18: Weft thread 19: Sinker Loop 20: Needle loop 21: Pile layer 22: Pile 23: Needle 24: Weft thread attachment / detachment part 25: Pile thread attachment / detachment part 26: Sinker 27: Tongue piece 28: Horizontal stitch 29: Vertical stitch 30: Relaxed stitch 31:Adhesive component 32: Heating container bottom plate 33: Zeolite 34: Bottom curtain 35: Mesh case 36: Curtain 37: Gravel 38: Needle bar 39: Tip of fluff 40:Fluff P: Tuffting Point

Claims

1. (1) A weft-knitted pile fabric (16) in which pile yarns (17) are knitted into a weft-knitted base fabric (15) in which weft yarns (18) are knitted in a flat knit structure, the pile yarns (17) are integrated with the weft yarns (18) to form needle loops (20) in a flat knit structure, and a sinker loop (19p) overlapping a sinker loop (19g) formed by the weft yarns (18) protrudes from the back of the needle loops (20) to form piles (22) whose two roots (13) are surrounded by the needle loops (20), (2) (a) Two piles at each base of two needles surrounded by one needle loop (20) form one pile, and the area of ​​the square is 10 x 10 cm, with one side 10 cm long in the course direction and one side 10 cm long in the wale direction intersecting at right angles. ２ The pile density (Θ), which is the number of piles per unit area, is 1050 piles / 100 cm ２ That's all. (3) Unit depth of pile layer (1 cm) and the unit area (100 cm ２ ) "Standard pile fiber weight" (δ) is 5g / 100cm ３ A weft-knitted pile fabric characterized by the above.

2. (1) The pile density (Θ), which is indicated by the number of piles per unit area with the interval α (cm) between two adjacent piles in the course direction and the interval β (cm) between two adjacent piles in the wale direction, is 1050 piles / 100 cm ２ That's all. (2) A weft-knitted pile fabric according to claim 1, characterized in that the pile yarn (17) is made of a large number of filaments (fibers) and the standard fineness of the weft yarn (18) is finer than the standard fineness of the pile yarn.

3. (1) The pile yarn (17) is mainly composed of crimped fibers and is bulkier than the weft yarn (18); (2) A weft-knitted pile fabric according to any one of claims 1 and 2, characterized in that the weft yarn (18) unwound from the weft-knitted pile fabric (16) is immersed in boiling water at 100°C for 60 minutes and the hot water shrinkage of the weft yarn (18) taken out is less than 10%.

4. (1) The pile yarn (17) is a multifilament yarn (multi-fiber yarn) consisting of many filaments (fibers) and having a standard fineness of 200 to 600 (standard dtex), (2) The standard fineness of the weft yarn (18) is 100 to 200 (standard dtex), which corresponds to 1 / 2 to 1 / 3 of the standard fineness of the pile yarn, and is a multifilament yarn (multi-fiber yarn). (3) A weft-knitted pile fabric according to any one of claims 1, 2 and 3, characterized in that a binder is applied to the back surface of the pile fabric (16) facing the pile surface, and the weft yarns (18) are enlarged by the binder.

5. 5. The weft-knitted pile fabric according to claim 4, wherein a water-repellent material is added to the binder applied to the back surface of the pile fabric (16).

6. A weft-knitted pile fabric according to any one of claims 1, 2, 3, 4 and 5, characterized in that a backing material (8) is laminated on the back surface of the pile fabric facing the pile surface (12).

7. 7. The weft-knitted pile fabric according to claim 6, characterized in that the adhesive component (31) interposed between the back surface of the pile fabric facing the pile surface (12) and the backing material (8) is adhered to the weft yarns (18) constituting the base fabric (15) without protruding into the pile layer (21).

8. The weft-knitted pile fabric according to any one of claims 1, 2, 3, 4, 5, 6 and 7, characterized in that it is three-dimensionally shaped by forging.

9. A weft-knitted pile fabric according to any one of claims 1, 2, 3, 4, 5, 6, 7 and 8, which constitutes a covering for an automobile foot mat (1).

10. A weft-knitted pile fabric as claimed in any one of claims 1, 2, 3, 4, 5, 6, 7, 8 and 9, characterized in that the pile spacing (β) in the wale direction is narrower than the pile spacing (α) in the course direction (β<α).

11. (1) (a) The number of piles Na (pieces) per 10 cm width in the course direction, which is calculated by dividing 10 cm of width in the course direction by the pile spacing (α) in the course direction (10 / α), (b) The product of 10 cm of the length in the wale direction divided by the pile spacing in the wale direction (β), (10 / β), and the number of pile stocks Nb (stocks) per 10 cm of the length in the wale direction, (100 / (α×β)) (c) The unit area of ​​the pile surface (10 cm×10 cm=100 cm ２ The pile density (Θ) per 100 cm ２ That's all. (2) Unit depth of pile layer (1 cm) and the unit area (100 cm ２ ) with a volume of 100 cm ３ The "standard pile fiber basis weight" (δ) in the three-dimensional space in the pile layer defined as a rectangular parallelepiped is 5 g / 100 cm ３ That's all. (3) A weft-knitted pile fabric as described in claim 1, characterized in that the pile yarn (17) is made of a large number of filaments (fibers) and the standard fineness of the weft yarn (18) is finer than the standard fineness of the pile yarn.

12. (1) A weft-knitted pile fabric (16) in which pile yarns (17) are knitted into a weft-knitted base fabric (15) in which weft yarns (18) are knitted in a plain knit structure, the pile yarns (17) are integrated with the weft yarns (18) to form needle loops (20) in a plain knit structure, and a sinker loop (19p) overlapping a sinker loop (19g) formed by the weft yarns (18) protrudes from the back of the needle loops (20) to form piles (22) whose two roots (13) are surrounded by the needle loops (20); (2) A weft-knitted pile fabric characterized in that the roots (13) of the pile (22) are not exposed at the corners (3) formed on the pile surface (12).

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