Surface Covering Material
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Solution Overview
Problem
Existing three-dimensional knitted fabrics for surface covering materials lack design properties with a sense of depth and durability, particularly in preventing pull-out and fluff generation when rubbed by hard protrusions like hook sections of a hook-and-loop fastener.
Innovation Solution
A surface covering material comprising a three-dimensional knitted fabric with a front/back double-layer structure and connecting thread, where pattern threads are inlay stitched into the openings of the front layer knitted fabric, with specific dimensions and stitch densities to enhance design properties and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If insertion threads are used to bind stitch rows forming ridges to prevent distortion and shifting, then form stability is improved, but design property with sense of depth is not enhanced and durability including fluff resistance and pull-out resistance remains insufficient
Solution Approach 1:
The front layer knitted fabric is segmented into multiple stitch rows with alternating high and low positions, forming a ridged structure. Insertion threads are selectively placed only in high-position stitch rows, creating a segmented pattern that provides both structural stability and design depth while reducing thread density to improve durability.
Solution Approach 2:
The insertion threads are distributed non-uniformly, appearing only in high-position stitch rows and absent in low-position stitch rows. This local quality variation creates a sense of depth in the design while reducing overall thread density, thereby improving fluff resistance and pull-out resistance compared to uniform thread distribution.
2Stability of the object's composition
If insertion threads are distributed uniformly across all stitch rows, then form stability is maintained, but design property with sense of depth is not enhanced and fluff resistance deteriorates
Solution Approach 1:
Instead of distributing insertion threads uniformly across all stitch rows, the invention applies partial action by placing threads only in high-position stitch rows. This selective placement provides sufficient form stability for the ridged structure while reducing overall thread density, thereby minimizing fluff generation during rubbing.
3Shape
If floating threads are inlay stitched into the front layer knitted fabric, then design property is enhanced, but durability including fluff resistance deteriorates because threads float on the surface
Solution Approach 1:
The insertion threads are preliminarily integrated into the knitted fabric structure during the knitting process itself, rather than being added as floating threads afterward. The threads are incorporated into high-position stitch rows and secured by the knitting mechanism, ensuring they are firmly embedded in the fabric structure before any rubbing or wear occurs, thereby preventing fluff generation while maintaining design property.
Data Source
AI summary
Provided is a surface covering material such as a sheet for a seat in a vehicle or as furniture, or upholstery for a vehicle, the surface covering material exhibiting high design properties with a sense of depth achieved by an inlay-knitted pattern yarn, while at the same time being capable of suppressing fluff and the pattern yarn from being pulled out even if the surface is rubbed by hard protrusions such as the hook part of a hook-and-loop fastener. This surface covering material is composed of a three-dimensional knitted material comprising: two layers of knitted fabric consisting of a front layer and a back layer; and a joint layer consisting of joint yarns that join the two front/back layers of knitted fabrics together. The surface covering material is characterized in that the front layer knitted fabric has openings and a pattern yarn is inlay-knitted into the openings.