Method for Forming Three-Dimensional Patterns using Double Raschel Knitted Fabric

Abstract

The present invention relates to a method for forming a three-dimensional pattern using a double Raschel knitted fabric, and more particularly, to a method for forming a three-dimensional pattern using a double Raschel knitted fabric, in which the facilitation of formation of visually aesthetic patterns can be ensured through a simple process during the surface-molding of the double Raschel knitted fabric having a feeling of volume and a cushion feeling, and in which the double Raschel knitted fabric can be given an adhesive property or a high abrasion resistance, or an adhesive property and a high abrasion resistance.

Claims

1. A method for forming a three-dimensional pattern using a double Raschel knitted fabric composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2, the method comprising surface-molding the double Raschel knitted fabric into the three-dimensional pattern by compressing the surface of the double Raschel knitted fabric at a temperature of 100-200 C. and a pressure of 10-70 kg/cm.sup.2 for 10-60 seconds using a mold formed with an engraved part so that a protruded part 20a is formed at a portion of the double Raschel knitted fabric, which corresponds to the engraved part of the mold, and a compressed part 20b is formed at the remaining portion other than the protruded part 20a of the double Raschel knitted fabric to thereby form the three-dimensional pattern.

2. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a TPU yarn 22, wherein the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin, wherein the intermediate layer L3 thereof is formed of a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

3. The method according to claim 1, wherein the upper layer L1 and the intermediate layer L3 of the double Raschel knitted fabric are formed of a fabric yarn 23, wherein the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

4. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, wherein the lower layer L2 and the intermediate layer L3 thereof are formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

5. The method according to claim 1, wherein the upper layer L1 and the lower layer L2 of the double Raschel knitted fabric are formed of a yarn 21 coated with a hotmelt resin, wherein the intermediate layer L3 thereof is formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

6. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, wherein the lower layer L2 thereof is formed of a TPU yarn 22, wherein the intermediate layer L3 thereof is formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2, wherein the fabric yarn 21c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention when taken in conjunction with the accompanying drawings, in which:

[0028] FIG. 1 is a top plan view showing a state in which a three-dimensional pattern is formed on the surface of a double Raschel knitted fabric according to a first embodiment of the present invention;

[0029] FIG. 2 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a first embodiment of the present invention;

[0030] FIG. 3 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a second embodiment of the present invention;

[0031] FIG. 4 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a third embodiment of the present invention;

[0032] FIG. 5 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a fourth embodiment of the present invention;

[0033] FIG. 6 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a fifth embodiment of the present invention;

[0034] FIG. 7 is a cross-sectional view showing a structure of a double Raschel knitted fabric according to a sixth embodiment of the present invention;

[0035] FIG. 8 is a cross-sectional view showing a structure of a yarn coated with a hotmelt resin applied to the present invention; and

[0036] FIGS. 9 and 10 are cross-sectional views showing a structure of a double Raschel knitted fabric on which a cover fabric is laminated according to the present invention.

EXPLANATION ON SYMBOLS

[0037] 20a: protruded part

[0038] 20b: compressed part

[0039] L1: upper layer

[0040] L2: lower layer

[0041] L3: intermediate layer

[0042] 21: yarn coated with a hotmelt resin yarn

[0043] 21a: core

[0044] 21b: sheath

[0045] 21c, 23: fabric yarn

[0046] 21d: hotmelt resin

[0047] 22: TPU yarn

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] The present invention for achieving the above-mentioned effects is directed to a method for forming a three-dimensional pattern using a double Raschel knitted fabric. In the meantime, in the detailed description and the accompanying drawings, illustration and explanation on the construction and operation which a person skilled in the art can easily understand will be briefly made or will be omitted to avoid redundancy. In particular, illustration and explanation on the detailed technical construction and operation of elements, which have no direct connection with the technical features of the present invention, will be omitted, and only the technical constructions directly related with the present invention will be briefly illustrated and explained.

[0049] Hereinafter, a method for forming a three-dimensional pattern using a double Raschel knitted fabric according to the present invention will be described in detail.

[0050] As shown in FIG. 1, the method for forming a three-dimensional pattern using a double Raschel knitted fabric according to the present invention includes surface-molding the double Raschel knitted fabric into the three-dimensional pattern by compressing the surface of the double Raschel knitted fabric at a temperature of 100-200 C. and a pressure of 10-70 kg/cm.sup.2 for 10-60 seconds using a mold formed with an engraved part (at this time, the types of the mold and the engraved part may be modified variously depending on designs) so that a protruded part 20a is formed at a portion of the double Raschel knitted fabric, which corresponds to the engraved part of the mold, and a compressed part 20b is formed at the remaining portion (i.e., a portion where the engraved part of the mold is not formed) other than the protruded part 20a of the double Raschel knitted fabric to thereby form the three-dimensional pattern. Herein, if the surface-molding conditions are out of the above range, the three-dimensional pattern may not be formed properly.

[0051] In the meantime, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, a first embodiment, a fifth embodiment and a sixth embodiment may be given an adhesive property (or tackiness) and a high abrasion resistance, a second embodiment and a fourth embodiment may be given a high abrasion resistance, and a third embodiment may be given an adhesive property.

[0052] Herein, the double Raschel knitted fabric is produced by a knitting process as described above. In other words, the double Raschel knitted fabric is a known knitted fabric knitted by a typical double Raschel warp knitting machine, i.e., a warp knitting method in which a whole fabric texture is formed in a warp direction, i.e., in a vertical direction in the knitting process. That is, the knitting type, method and apparatus of the double Raschel knitted fabric have been known in various manners, but are not particularly limited and any known knitting type, method and apparatus of the double Raschel knitted fabric can be applied to the present invention.

[0053] First, in the first embodiment of the present invention, as shown in FIG. 2, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 of the double Raschel knitted fabric is formed of a TPU yarn 22, the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin, and the intermediate layer L3 thereof is formed of a fabric yarn (jet spun yarn) 23.

[0054] In other words, the yarn 21 coated with a hotmelt resin formed on the lower layer L2 gives an adhesive property to the double Raschel knitted fabric, the TPU yarn 22 formed on the upper layer L1 improves an abrasion resistance of the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0055] Further, the UPU yarn 22 formed on the upper layer L1 facilitates the formation of patterns during the surface-molding of the double Raschel knitted fabric.

[0056] In this case, the yarn 21 coated with a hotmelt resin serves to gives an adhesive property to the double Raschel knitted fabric, and as shown in FIG. 8, it is formed such that a hotmelt resin 21d is coated on the outer surface of a fabric yarn 21c consisting of a core 21a and a sheath 21b in an amount of 0.03-0.3 g/m.sup.2. If the coating content of the hotmelt resin 21d is less than 0.03 g/m.sup.2, the adhesive property may be deteriorated, and if the coating content of the hotmelt resin 21d exceeds 0.3 g/m.sup.2, a defect may occur during the double Raschel knitting process due to an increase in the amount of the hotmelt resin 21d. Meanwhile, the coating content of the hotmelt resin 21d may vary in the extent being out of the above range depending on the kind or use environment of a product applied to the present invention.

[0057] In this case, examples of the fabric yarn 21c included in the yarn 21 coated with a hotmelt resin may include a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and examples of the hotmelt resin 21d may include a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.

[0058] Herein, each of the examples of the hotmelt resin 21d may be coated on the fabric yarn 21c irrespective of the kind of the fabric yarn 21c, but the hotmelt resin 21d and the fabric yarn 21c may be selected in consideration of the fusion property of the fabric yarn 21c and the hotmelt resin 21d through the coating process. In other words, if the polyester yarn is selected as the fabric yarn 21c, the polyurethane resin is preferably coated as the hotmelt resin 21d. If the nylon yarn is selected as the fabric yarn 21c, the acrylic resin or the polyimide resin is preferably coated as the hotmelt resin 21d. In addition, if the cotton yarn is selected as the fabric yarn 21c, the ethylene vinyl acetate resin or the polyolefin resin is preferably coated as the hotmelt resin 21d.

[0059] In the meantime, the TPU yarn 22 refers to a yarn produced by extruding a thermoplastic polyurethane (TPU) resin, which is a sort of yarn that is already known in the art, and thus a detailed description thereof will be omitted to avoid redundancy. Further, it is obvious to those skilled in the art that the TPU yarn 22 is formed of the above TPU resin so that it is relatively excellent in its abrasion resistance compared to a general fabric yarn.

[0060] In addition, examples of the fabric yarn 23 used in the intermediate layer L3 may include a polyester yarn, a nylon yarn, a mono yarn, and a cotton yarn, which are used alone or in combination of two or more thereof.

[0061] In addition, in the second embodiment of the present invention, as shown in FIG. 3, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 is formed of a TPU yarn 22, and the lower layer L2 and the intermediate layer L3 are formed of a fabric yarn 23.

[0062] In other words, the TPU yarn 22 formed on the upper layer L1 improves an abrasion resistance of the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0063] Further, the UPU yarn 22 formed on the upper layer L1 facilitates the formation of patterns during the surface-molding of the double Raschel knitted fabric.

[0064] In addition, in the third embodiment of the present invention, as shown in FIG. 4, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 and the intermediate layer L3 of the double Raschel knitted fabric are formed of a fabric yarn 23, and the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin.

[0065] In other words, the yarn 21 coated with a hotmelt resin, formed on the lower layer L2 gives an adhesive property to the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0066] Further, in the fourth embodiment of the present invention, as shown in FIG. 5, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, and the lower layer L2 and the intermediate layer L3 thereof are formed a fabric yarn 23.

[0067] In other words, the hotmelt resin-coated yarn 21 formed on the upper layer L1 improves an abrasion resistance of the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0068] Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1 facilitates the formation of patterns during the surface-molding of the double Raschel knitted fabric.

[0069] In addition, in the fifth embodiment of the present invention, as shown in FIG. 6, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 and the lower layer L2 of the double Raschel knitted fabric are formed of a yarn 21 coated with a hotmelt resin, and the intermediate layer L3 thereof is formed a fabric yarn 23.

[0070] In other words, the hotmelt resin-coated yarn 21 formed on the upper layer L1 improves an abrasion resistance of the double Raschel knitted fabric, the yarn 21 coated with a hotmelt resin, formed on the lower layer L2 gives an adhesive property to the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0071] Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1 facilitates the formation of patterns during the surface-molding of the double Raschel knitted fabric.

[0072] In addition, in the sixth embodiment of the present invention, as shown in FIG. 7, in the double Raschel knitted fabric used in the present invention, which is composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2 to give a feeling of volume and a cushion feeling, the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, the lower layer L2 thereof is formed of a TPU yarn 22, and the intermediate layer L3 thereof is formed a fabric yarn 23.

[0073] In other words, the hotmelt resin-coated yarn 21 formed on the upper layer L1 improves an abrasion resistance of the double Raschel knitted fabric, and the intermediate layer L3 formed of the fabric yarn 23 gives a feeling of volume and a cushion feeling to the double Raschel knitted fabric.

[0074] Besides, in the sixth embodiment, the knitting structure of the TPU yarn 22 is visibly observed from the outside of the upper layer L1 during the forming process due to a difference (typically, the melting point of the TPU yarn 22 is higher than that of the hotmelt resin-coated yarn 21) in the melting point between the hotmelt resin-coated yarn 21 forming the layer L1 and the TPU yarn 22 forming the lower layer L2 so that formability and thus the aesthetic value of the exterior appearance of the double Raschel knitted fabric can be improved.

[0075] Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1 facilitates the formation of patterns during the surface-molding of the double Raschel knitted fabric.

[0076] In the meantime, the hotmelt resin-coated yarn 21, the TUP yarn 22 and the fabric yarn 23, which are used in each of the above embodiments, have been described in the first embodiment, and thus the detailed description thereof will be omitted to avoid redundancy.

[0077] Further, in each of the above embodiments, in the case of the hotmelt resin-coated yarn 21 or the TPU yarn 22 forming the upper layer L1 or the lower layer L2, the hotmelt resin-coated yarn 21, the TPU yarn 22 and the fabric yarn 23 may be mixed to form each layer. Specifically, the hotmelt resin-coated yarn 21 may be mixed with the TPU yarn 22 or the fabric yarn 23, and the TPU yarn 22 may be mixed with the hotmelt resin-coated yarn 21 or the fabric yarn 23, but are not limited thereto and various yarns or functional yarns may be mixed.

[0078] In other words, the double Raschel knitted fabric of the present invention is given an adhesive property and a high abrasion resistance as in the first embodiment, the fifth embodiment and the sixth embodiment besides a feeling of volume and a cushion feeling, or is given an adhesive property as in the third embodiment. Alternatively, as in the sixth embodiment, formability and thus the aesthetic value of the exterior appearance of the double Raschel knitted fabric are improved so that its use range and efficiency can be further extended.

[0079] Meanwhile, in the double Raschel knitted fabric having the above structure, as shown in FIGS. 9 and 10, in the case where a cover fabric 200 is laminated on the top surface of the upper layer L1 of the double Raschel knitted fabric, the lower layer L2 (i.e., a layer contacting with a bottom surface) is formed of the hotmelt resin-coated yarn 21 or the TPU yarn 22 so that a non-slip property relative to the bottom surface can be improved, and a variety of safety accidents can be prevented as well as a convenience in use can be enhanced in the manufacture of a mat or seat using the non-slip property.

[0080] In this case, in laminating the cover fabric 200 on the top surface of the upper layer L1 of the double Raschel knitted fabric, the cover fabric 200 and the top surface of the double Raschel knitted fabric are boned to each other by means of a general hotmelt film so that the adhesive property of the cover fabric 200 can be improved. Further, the double Raschel knitted fabric may be applied to various kinds of mats or seats by sewing according to the shape of a pattern formed on the cover fabric 200.

[0081] As described above, while the method for forming a three-dimensional pattern using a double Raschel knitted fabric according to the present invention has been described and illustrated in connection with specific exemplary embodiments with reference to the accompanying drawings, it will be readily appreciated by those skilled in the art that various modifications and changes can be made to the present invention within the technical spirit and scope of the present invention defined in the claims.