TWO LAYER FABRIC AND ARTICLES COMPRISING THE SAME

Abstract

The present application relates to a two-layer fabric and an article including the same.

Claims

1. A two-layer fabric comprising: a first fabric layer (L1) having a predetermined pattern (P1); and a second fabric layer (L2) having a predetermined pattern (P2), wherein a protrusion pattern (P3) integrally formed with the fabric layer is formed on the surface of at least one of the fabric layers (L1, L2), and wherein the protrusion pattern (P3) is formed in a size that occupies an interval of 5 to 100 threads, provided that the threads refer to a strand of warp and weft threads forming the patterns (P1, P2) of the fabric layers (L1, L2).

2. The two-layer fabric according to claim 1, wherein: the protrusion pattern (P3) is formed separately at intervals of 5 to 50 threads.

3. The two-layer fabric according to claim 1, wherein: the pattern (P1) of the fabric layer (L1) and the pattern (P2) of the fabric layer (L2) are the same as or different from each other.

4. The two-layer fabric according to claim 1, wherein: the pattern (P1) of the fabric layer (L1) and the pattern P2 of the fabric layer L2 are each independently a 11 weave, a 22 weave, a 33 weave, a satin weave, a warp rib weave, a weft rib weave, or its mixed weave.

5. The two-layer fabric according to claim 1, wherein: the density of the warp and weft threads forming the patterns (P1, P2) of the fabric layers (L1, L2) is 40 to 80 th/inch.

6. The two-layer fabric according to claim 1, wherein: the protrusion pattern has a mesh shape.

7. The two-layer fabric according to claim 1, wherein: the density of warp and weft threads forming the protrusion pattern (P3) is 20 th/inch or less.

8. The two-layer fabric according to claim 1, wherein: the patterns P1, P2 and P3 are formed of at least one fiber selected among a polyester fiber, a nylon fiber, an aramid fiber, a polyketone fiber, a carbon fiber and a cellulose fiber.

9. The two-layer fabric according to claim 8, wherein: the fiber has a fineness of 300 to 1500 dtex.

10. The two-layer fabric according to claim 1, which further comprises a coating layer formed on one surface of the fabric layers (L1, L2), wherein the resin coating layer comprises at least one of silicone and urethane resin.

11. The two-layer fabric according to claim 10, wherein: the protrusion pattern (P3) is formed on another one surface opposite to the one surface on which the resin coating layer is formed.

12. The two-layer fabric according to claim 10, wherein: a coating amount of the resin coating layer is in the range of 30 to 150 g/m.sup.2.

13. A method for producing a two-layer fabric, comprising: simultaneously weaving a first fabric layer (L1) and a second fabric layer (L2) separated from each other using one-piece woven (OPW) process, and forming a protrusion pattern (P3) integrally formed with the fabric layers on the surface of at least one of the fabric layers (L1, L2), wherein the protrusion pattern (P3) is formed in a size that occupies an interval of 5 to 100 threads, provided that the threads refer to a strand of warp and weft threads forming the patterns (P1, P2) of the fabric layers (L1, L2).

14. The method for producing a two-layer fabric according to claim 13, wherein: the protrusion pattern (P3) is formed in a mesh shape.

15. An article comprising the two-layer fabric according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0059] FIG. 1 schematically depicts a two-layer fabric that can be used for an airbag according to an embodiment of the present application. As shown in the figure, the two-layer fabric can form a non-inflation part (A), an inflation part (B) and a joint part (C).

[0060] FIG. 2 is a photograph of the surface of the fabric layers (L1, L2) and the protrusion pattern (P3) according to an embodiment of the present application. Specifically, FIG. 2a is an image of a state in which a plurality of protrusion patterns (P3) are formed on an inside surface of the first fabric layer 10, among the surfaces (uncoated surface as an inside surface) facing each other of the first fabric layer (L1) 10 and the second fabric layer (L2) 20. And, FIG. 2b is an enlarged photograph of the protrusion pattern (P3), which shows a piece of protrusion pattern 30 formed while occupying a predetermined area with a predetermined thread interval size (e.g., 5 to 100 thread interval size). On the other hand, FIG. 2c is an image of the coating surface, which is a surface opposite to the inside surface of the fabric layer on which the protrusion pattern (P3) is formed.

[0061] FIG. 3 is an image for explaining a mesh-shaped protrusion pattern formed on the surface of the fabric layer. Specifically, FIG. 3a is an image obtained by photographing the pattern (P1 or P2) of the fabric layer (L1 or L2), and FIG. 3b is an image obtained by photographing a mesh-shaped protrusion pattern (P3) formed on the fabric layer pattern (P1 or P2) of FIG. 3a. At this time, in the embodiment of FIG. 3b, the density of the fabric layer pattern is 5748 th/inch, and the density of the protrusion pattern is 810 th/inch. One protrusion pattern is sized to occupy 36 thread intervals in the weft and warp directions, and each protrusion pattern can be formed separately at an interval of 8 threads in the weft and warp directions.

[0062] FIG. 4 is a view for explaining a puncture test described later.

[0063] FIG. 5 is a view for explaining a tear strength test described later.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0064] Hereinafter, the action and effect of the invention will be described in more detail with reference to specific examples of the invention. However, these examples are presented for illustrative purposes only and the scope of the invention is not limited thereby in any way.

EXAMPLE AND COMPARATIVE EXAMPLE

Example 1

[0065] A two-layer fabric was prepared by the OPW weaving process using a jacquard machine. The fiber used in preparing the two-layer fabric was a PET fiber (Secura-Stelen) by Kolon, and the pattern (P1) of the first fabric layer and the pattern (P2) of the second fabric layer were each woven into a 11 plain weave. At this time, the protrusion pattern as shown in FIG. 3b was formed on the inside surface of the first fabric layer (i.e., the inside surface of the first fabric layer facing one surface of the second fabric layer).

[0066] Then, the outside surface of each fabric layer was coated with a urethane resin (using Covestro DLU coating agent) (coating amount of 38 g/m.sup.2), and then cured at a temperature of 80 to 180 C. for about 1.5 minutes in a hot air chamber.

[0067] The thickness of the coated two-layer fabric prepared as above was 0.43 mm, and the total weight was 302 g/m.sup.2.

Comparative Example 1

[0068] A coated fabric was prepared in the same manner, except that the protrusion pattern P3 was not formed on the inside surface of the two-layer fabric.

[0069] The thickness of the coated two-layer fabric prepared as above was 0.37 mm, and the total weight was 297 g/m.sup.2.

Comparative Example 2

[0070] A coated fabric was prepared in the same manner, except that the protrusion pattern (P3) was not formed on the inside surface of the two-layer fabric and the outside surface of each fabric layer was coated with silicone resin (Dow Corning DC3760 coating agent was used) (coating amount of about 75 g/m.sup.2).

[0071] The thickness of the coated two-layer fabric prepared as above was 0.36 mm, and the total weight was 340 g/m.sup.2.

[0072] Experiment 1: Evaluation of Mechanical Properties

[0073] 1. Puncture Test (Puncture Force, N)

[0074] The physical properties of the fabric were evaluated according to ASTM F1342. Specifically, the fabrics prepared in Examples and Comparative Examples were fixed to an ASTM F1342 Puncture Strength measuring jig, and then Probe A was penetrated into the Puncture Guide Hole of the jig at a rate of 50.8 cm/min. Then, the load and the degree of elongation when the puncture occurred in the fabric were measured. ASTM F1342 Puncture Strength Measurement Jig and Probe A were manufactured according to the standard shown in FIG. 4.

[0075] 2. Tear Strength Test (Tear Force, N)

[0076] The properties of the fabric were evaluated according to ISO 13937-2. Specifically, the fabrics prepared in Examples and Comparative Examples were cut into trouser-shaped specimens as shown in FIG. 5a (unit: cm), and both legs of the sample are tensioned at a speed of 100 mm/min in up and down direction. At this time, a Tear Strength graph according to time could be obtained as shown in FIG. 5b. The peaks of this graph were divided into 4 equal parts from the start to the end, and then the arithmetic mean of a total of 16 numerical values, including 2 maximum peaks and 2 minimum peaks, were calculated for each equal parts, thereby calculating the tear strength. The experimental results are shown in Table 1 below.

TABLE-US-00001 TABLE 1 Comparative Comparative Example 1 Example 1 Example 2 Puncture force (N) 45.3 41.0 27.1 Tear force Warp direction 344.4 227 290 (N) Fill direction 546.36 245 280

[0077] Experiment 2: Evaluation of Thickness, Weight and Foldability

[0078] When folding the fabric, the thickness can vary depending on the size and shape of the fabric. Thus, Example 2 and Comparative Example 3 were constructed using fabrics of the same shape and specification. Specifically, for the specimens of Example 2 and Comparative Example 3, the same polyurethane coating material was coated onto the same fabric (using PET 550 dtex/144f, OPW fabric having the weft and warp density of 5748 th/in was produced) in the same amount (about 35 gsm). At this time, the fabric has a rectangular sheet shape, and the area is A.

[0079] However, in the case of Example 2, a protrusion pattern (810 th/in (weftwarp) density) occupied by 36 threads in the weft and warp directions was formed on the fabric, and the protrusion pattern as described above was repeatedly positioned at intervals of 20 threads in the weft and warp directions, so that it was evenly formed on a partial area (a) of the fabric area (A) (1 layer). Further, in the case of Comparative Example 3, a reinforcement fabric occupying an area (a) (manufactured in the same manner as the prepared fabric, only the area is different) was backed onto the prepared fabric (2 layers).

[0080] The thickness, weight, and foldability of Example 2 and Comparative Example 3 were evaluated (arithmetic mean value for 5 measurements) as follows.

TABLE-US-00002 TABLE 2 Example 2 Comparative Example 3 Roll folding 89 mm 100 mm Thickness 0.43 mm 0.72 mm Weight 302 g/m.sup.2 545 g/m.sup.2 * Roll folding: Each specimen is rolled up from one end to form a cylindrical shape, and the circumference of the central part is measured. * Thickness: The thickness of each specimen * Weight: The weight per unit area of each specimen.