阅读说明：本技术 间隔针织物 (Spacer fabric ) 是由 S·米勒 R·诺伊迈尔 于 2020-04-24 设计创作，主要内容包括：本发明涉及一种间隔针织物(1),其具有面状的第一针织物层(2)、面状的第二针织物层(3)和连接所述针织物层(2、3)的间隔纱线(4),其中,第一针织物层(2)具有分别由多个线圈构成的开口(12),其中,第二针织物层(3)至少具有第一和第二纱线系统(13、15),并且第一纱线系统(13)的纱线沿着生产方向(P)在配设的恰好一个线圈纵列上延伸并且第二纱线系统(15)的纱线在沿生产方向(P)延伸的、彼此相邻的至少两个线圈纵列上引导。根据本发明,第二针织物层(3)也具有分别由多个线圈构成的开口(12’)。(The invention relates to a spacer knitted fabric (1) having a first planar knitted fabric layer (2), a second planar knitted fabric layer (3) and spacer yarns (4) connecting the knitted fabric layers (2, 3), wherein the first knitted fabric layer (2) has openings (12) each formed by a plurality of stitches, wherein the second knitted fabric layer (3) has at least a first and a second yarn system (13, 15), and the yarns of the first yarn system (13) run in exactly one assigned stitch row along a production direction (P) and the yarns of the second yarn system (15) are guided in at least two adjacent stitch rows running along the production direction (P). According to the invention, the second knitted fabric layer (3) also has openings (12') each formed by a plurality of stitches.)

1. A spacer knitted fabric (1) having a planar first knitted fabric layer (2), a planar second knitted fabric layer (3) and spacer yarns (4) connecting the knitted fabric layers (2, 3), wherein the first knitted fabric layer (2) has openings (12) each formed by a plurality of stitches, wherein the second knitted fabric layer (3) has at least a first and a second yarn system (13, 15), and the yarns of the first yarn system (13) extend in the production direction (P) on exactly one associated wale and the yarns of the second yarn system (15) are guided on at least two wales adjacent to each other extending in the production direction (P), characterized in that the second knitted fabric layer (3) has openings (12') each formed by a plurality of stitches.

2. The spacer knit (2) according to claim 1, characterized in that the second yarn system (15) is configured as a mesh inlay having a first sub-yarn system (15a) and a complementary second sub-yarn system (15 b).

3. The spacer knit (1) according to claim 2, characterized in that the two sub-yarn systems (15a, 15b) are constructed by means of two guide bars in a one-through-one-empty-warp or a two-through-two-empty-warp, respectively.

4. The spacer knitted fabric (1) according to claim 2 or 3, characterised in that the yarns of the second yarn system (15) alternately constitute, along the production direction (P), on the one hand, chaining loops (14') and, on the other hand, loops (16) selected from the group of warp knitted fabric, cloth, satin, velour and sateen.

5. The spacer knit (1) according to any one of claims 1 to 4, characterised in that the yarns of the first yarn system (13) constitute in an alternating sequence in the production direction (P) a pillar stitch (14') and are guided in a manner that does not constitute a stitch.

6. The spacer knit (1) according to any one of claims 1 to 5, characterized in that the planar first knit layer (2) has a greater extensibility in the production direction (P) and in the transverse direction (Q) than the second knit layer (3).

7. The spacer knit (1) according to claim 6, characterized in that the elongation determined at 25N (Newton) according to DIN ENISO 13934-1 is at least twice as high in the case of a planar first knit fabric layer (2) as in the case of a planar second knit fabric layer (3) for the production direction (P) and the transverse direction (Q).

8. The spacer knit (1) according to claim 6 or 7, characterized in that the elongation determined at 25N according to DIN EN ISO 13934-1 is between 25% and 60% in the case of the planar first knit fabric layer (2) for the production direction (P) and the transverse direction (Q).

9. The spacer knit (1) according to claim 6 or 7, characterized in that the elongation determined at 25N (Newton) according to DIN EN ISO 13934-1 is between 1.5% and 10% in the case of the planar second knit layer (3) for the production direction (P) and the transverse direction (Q).

10. The spacer knit (1) according to any one of claims 1 to 9, characterized in that the thickness is between 2mm and 20 mm.

11. The spacer knit (1) according to any one of claims 1 to 10, wherein the second knit layer (3) has multifilament smooth yarns and/or monofilament yarns.

12. The spacer knit (1) according to any one of claims 1 to 11, characterized in that the first knitted fabric layer (2) has a textured multifilament yarn.

Technical Field

The invention relates to a spacer knitted fabric having a first planar knitted fabric layer, a second planar knitted fabric layer and spacer yarns connecting the knitted fabric layers, wherein the first knitted fabric layer has openings each formed by a plurality of stitches, the second knitted fabric layer has at least a first and a second yarn system, and the yarns of the first yarn system extend in the production direction on exactly one assigned stitch column and the yarns of the second yarn system are guided via at least two adjacent stitch columns extending in the production direction. The spacer fabric is provided in particular as an elastic layer in a vehicle seat or trim part.

Background

The arrangement of the production direction and the transverse direction is common in the case of knitted textiles, wherein the production direction is also referred to as the knitting direction or the longitudinal direction. In the case of a spacer knit, the individual threads forming the knit extend in the production or knitting direction and therefore have a generally repeating knitting pattern, so that, for example, the spacer threads between the two knit layers, possibly also offset in the transverse direction, extend back and forth.

According to the usual definition of terms, the two flat knitted fabric layers have a course extending in the production direction and a course extending in the transverse direction.

The spacer knit is characterized by a light and breathable structure, wherein the spacer knit is elastic in the direction of its thickness due to the spacer yarns extending between the two knitted fabric layers. For this purpose, it is customary to provide individual filament yarns as spacer yarns, which have a relatively high recovery effect on account of their structure.

Due to the elastic properties, the spacer fabric can be arranged as a soft, elastic layer that enables air circulation in mattresses, upholstered furniture, clothing or shoes. Spacer knits are also used in the automotive industry as technical textiles, for example for ventilated seats and seat covers, wherein the spacer knits enable good profiling on the basis of their cushion properties and very good recovery capability.

In addition, however, spacer fabrics in the automotive industry are also particularly suitable for underfills in the case of other applications (for example furniture construction). Spacer knits are therefore used in the automotive industry for interior trim, wherein composites with spacer textiles and pressed-on textile layers (e.g. leather, synthetic leather or decorative films) can be used for decorating roofs, dashboards, center consoles and interior sides of vehicle doors.

In this case, the composite material or composite assembly with the spacer fabric and the cover and decorative layer is usually connected to an underlying, either rigid or flexible base structure. For example, composite components for interior trim or in the production of furniture can be applied to rigid substructures or, in the case of seat or seating surfaces, to flexible substructures.

The following advantages are obtained not only in the case of rigid, but also flexible substructures: rounding, bending or other three-dimensional shaping can be compensated to some extent by the spacer knit, wherein in many cases excessively severe deformations and in particular wrinkling of the overlay and the decorative layer can be prevented. In addition, a particularly comfortable soft touch is obtained for the user on account of the flexibility of the spacer knit, but the predetermined shape, at least after elastic recovery, is also retained on account of the elastic recovery force of the spacer knit.

Although spacer knits are in part far superior to other elastic materials in these properties, there is still a need for further improvement of the mechanical properties of spacer knits, particularly in the case of products of complex or demanding shaping and in the case of products of particularly long service life.

DE 102010010524B 4 discloses a spacer knit and a composite component made of the spacer knit and a covering and decorative layer, wherein the composite component provides reduced tear resistance at several points for placement over an airbag or an airbag flap.

For this purpose, the two planar knitted fabric layers of the spacer knit are each formed from a base yarn system and a further yarn system, wherein a first part of the course is formed at least from the base yarn system and a second part of the course is formed from the second yarn system, wherein the yarns of the base yarn system are guided without forming loops in the case of the second part of the course and the knitted fabric layer on the second part of the course has a lower tear resistance in the production direction than the knitted fabric layer on the first part of the course. In other words, the weakening lines extending in the transverse direction are formed by omitting stitches, wherein the respective weakening lines are arranged in the two knitted fabric layers overlapping one another or with a small deviation, so that the two knitted fabric layers are identically constructed with respect to their functionality. Accordingly, the two knitted fabric layers have the same or at least similar mechanical properties not only with regard to their tear resistance but also with regard to their bending strength and extensibility.

A spacer knit according to the preamble of claim 1 is known from DE 102016125881B 3, wherein the two knit layers of the spacer knit are fundamentally different in terms of their structural and mechanical properties. In the case of composite components with spacer knits, these different mechanical properties are used in a particularly advantageous manner. One of the two knitted fabric layers is well extensible in the production direction and in the transverse direction, while the opposite covering layer has only a very small extensibility in the production direction (knitting direction) and in the transverse direction. The knit layer with low extensibility is arranged adjacent to the cover and decorative layer, so that the well extensible knit layer and the cover and decorative layer are opposite each other via the spacer yarns.

In the case of the bending of the spacer knit known from DE 102016125881B 3 or of the composite material formed from the spacer knit, completely different properties are obtained than in the case of a uniform layer material. In the case of uniform layer materials, such as thick plastic films or cut foams, the neutral fibers are usually in the center of the thickness when bent, whereas in the case of the spacer knit according to DE 102016125881B 3 the neutral fibers (i.e. the fibers which do not undergo substantial stretching or compression) when bent lie on a knit layer with little extensibility, which is situated directly below the covering and decorative layer. These properties of the spacer knit-based and in particular of the directly connected knitted fabric layer with low extensibility protect the covering and the decorative layer extremely well from wrinkling, being pressed or the like. In the case of a uniform, concave or convex curvature, the opposite, well-extensible knitted fabric layer is correspondingly lengthened or shortened, which also contributes to an excellent protection of the covering and decorative layer.

The composite component known from DE 102016125881B 3 is distinguished by outstanding properties if a large, uniformly curved or arched surface is to be provided or if cushioning is to be applied underneath.

However, improvements are still required in the composite assembly in terms of alternative spatial arrangements.

Disclosure of Invention

Against this background, the object of the present invention is to provide a spacer knit with good mechanical properties and good air permeability, which allows an extended range of use.

The subject of the invention and the solution of said object are a spacer knit according to claim 1.

Proceeding from the preamble of claim 1, according to the invention it is provided that: the less stretchable knitted fabric layer (referred to herein as a second knitted fabric layer) has openings each made up of a plurality of stitches. In the context of this embodiment, the two knitted fabric layers then have corresponding openings, which are, however, designed differently. That is, in the case of the second knit layer, care must be taken to: without providing excessive extensibility due to the configuration of the openings.

According to the invention, the two knitted fabric layers have openings each formed by a plurality of stitches. Each textile structure is not completely tight, so that a certain opening remains between the individual yarns at all times. The feature that the knitted fabric layer has openings each formed by a plurality of stitches is not intended to mean this conventional textile structure, but rather a special design of the respective knitted fabric layer or of the two knitted fabric layers, so that there are openings formed which are larger than the stitches or the intermediate spaces between two individual stitches.

The corresponding opening is realized in practice by a mesh inlay (fillettegrg), for which purpose the operation is typically carried out by means of two thread guide bars (legescheinen) which are not completely occupied. Corresponding lapping or web patterns are described, for example, in pages 188 and 189 of the specialist book Wirkerei und Strickerei, technology-Bindungen-Produktionsbeisele, 6 th edition 2014, German specialist book publisher, by Marcus Oliver Weber/Klaus-Peter Weber.

Particularly good air or fluid transport in general in the thickness direction is also possible due to the corresponding openings. According to DE 102016125881B 3, corresponding openings are known only for knitted fabric layers with greater extensibility. According to this prior art, the construction solution is also based on the following recognition: in the case of the usual inlay yarn patterns, the extensibility can be improved based on a grid-like or net-like structure only.

Despite this knowledge, provision is made according to the invention for: the two knitted fabric layers have openings each made up of a plurality of stitches. However, in the case of a second knitted fabric layer which can be extended to a lesser extent within the scope of the invention, it is then possible to provide a knitting pattern which, although forming corresponding openings, has only a relatively small extensibility, i.e. these openings do not contribute to a significantly increased extensibility.

An important contribution to this is that within the scope of the invention the second knitted fabric layer has a first yarn system, wherein the yarns of the first yarn system run in the production direction over exactly one allocated wale, so that a high tensile force is achieved in the production direction by the yarns of the first yarn system.

As is also known from DE 102016125881B 3, the first yarns of the first yarn system can be guided in the production direction in an alternating sequence in the form of a pillar stitch or without a stitch. For example, for every two courses, it can be provided that the chaining stitch is formed and that the thread is guided without forming a stitch. However, if the threads are guided without forming loops, they can be guided around the respective needles during the knitting process, so that in practice they are also referred to as "single-needle weft insertion".

In order to form openings in the second knitted fabric layer which can be extended to a lesser extent, the second yarn system can be formed as a mesh inlay having a first partial yarn system and a complementary second partial yarn system. The sub-yarn systems, which are typically formed by means of correspondingly assigned guide bars, are referred to as second yarn systems in the context of the present invention on the basis of an identical inlay pattern, but inverted. According to a mesh inlay known per se, it can be provided here that: the two sub-yarn systems are formed by two guide bars in a one-through one-empty-warp-threading method or a two-through two-empty-warp-threading method. In addition, further inlay patterns are known in principle, which are also conceivable within the scope of the invention. The respective opening can extend, for example, over two courses.

And in order to achieve as small an extension as possible in the production direction and in the transverse direction despite the formation of the openings, a particularly preferred embodiment of the invention provides that the yarns of the second yarn system alternately form, along the production direction, on the one hand a pillar stitch and, on the other hand, a stitch selected from the group of warp knitted fabrics, cloths, satin, velour and sateen. The connection of the individual wales in the transverse direction is achieved by the stitches selected from the group of warp-knitted fabrics, cloth, satin, velour and sateen, so that a small extensibility in the transverse direction is obtained. However, if the yarns of the second yarn system, i.e. the first partial yarn system and the complementary second partial yarn system, additionally form a pillar stitch, the tensile strength in the production direction is additionally increased and thus the extensibility is also reduced.

Even if the second knitted fabric layer has openings each made up of a plurality of stitches, these openings are desirably smaller than the openings of the first knitted fabric layer. The yarns of the second yarn system are able to alternately constitute, along the production direction, n >1 pillar stitches and, on the other hand, m >1 stitches selected from the group of warp knitted fabrics, cloth, satin, velour and sateen. In the simplest case, two coils of the type mentioned are each arranged one after the other in the production direction, but the invention is not limited to this embodiment.

Within the scope of the invention, the spacer knit can have, for example, 10 to 35, in particular 18 to 28, courses per centimeter in the production direction.

In the transverse direction, there are usually 4 to 13, preferably 6 to 10, wales per cm.

The pile column density per square centimeter is then between 144 and 728, preferably between 200 and 560, with the assigned guide bars preferably being covered with spacer yarns. The number of courses and wales can be determined in accordance with DIN EN 14971.

The weight per unit area can typically be in the range of 200g/m²And 750g/m²Preferably 350g/m²And 600g/m²In the meantime.

According to the invention and in contrast to the prior art according to DE 102016125881B 3, the first textile layer facing the planar surface covering the decorative layer has a greater extensibility in the production direction and in the transverse direction than the second textile layer. When the spacer knit is bent under tension, it is easy to determine the different extensibility. It is then possible to directly determine by hand which of the two layers of knitting is more easily extended.

The greater extensibility of the second knitted fabric layer is related to the stretching forces that are usual without damaging the material.

Within the scope of the present invention, the extensibility or elongation in the production direction and in the transverse direction can also be quantified according to DIN EN ISO 13934-1: 2013-08. If the stretch properties of the entire spacer knit are to be determined according to the prior art, the standard "textile-stretch properties of the textile surface-part 1" can also be used. However, it is considered in the prior art that the stretch properties for the two flat knitted fabric layers are to be determined, and the highest tensile force does not have to be determined here.

In contrast, in order to compare the two knitted fabric layers, the extension at a predefined tensile force of, for example, 25N (newtons) is determined and compared within the scope of the invention. According to a predetermined standard, spaced-apart knitted fabric strips having a width of 50mm can be formed for this purpose. An initial length can be determined along the longitudinal direction of the strips and then arranged to be sandwiched between the test jaws of the extension device. The spacer thread can then be cut off in order to be able to finally test the planar first and second knitted fabric layers separately from one another with regard to their elongation properties.

A preferred embodiment of the invention provides that, taking into account the test, the extent of the first planar knitted fabric layer, determined according to DIN EN ISO 13934-1 at a tensile force of 25N, is at least twice as great as the extent of the second planar knitted fabric layer, with regard to the production direction and the transverse direction, so that an elongation of at least 2: 1, in the presence of a catalyst. Without any problem, this ratio can also reach, for example, 3: 1. 5: 1 or 7: 1. but can also reach 10: 1 or higher.

In this case, it can be provided that the elongation, determined according to DIN EN ISO 13934-1 at a tensile force of 25N, for the production direction and the transverse direction is between 25% and 60%, in particular between 30% and 48%, in the case of a planar first knitted fabric layer.

The elongation determined to DIN EN ISO 13934-1 at a tensile force of 25N for the production direction and the transverse direction is only between 1.5% and 10%, in particular between 2% and 7%, in the case of a flat second knitted fabric layer.

In order to achieve particularly low elongations independently of the specific knitting pattern for the second knitted fabric layer, it is provided according to a preferred embodiment of the invention that the second knitted fabric layer has or consists of multifilament smooth yarns and/or monofilament yarns. The respective yarns then have only a relatively small elongation in their longitudinal direction, in particular if they are composed of common thermoplastics, such as polyesters, polyamides or polyolefins, such as polyethylene or polypropylene.

In order to achieve good extensibility in the first knitted fabric layer, it is instead preferably provided that the first knitted fabric layer has or consists of textured multifilament yarns. In the case of a textured multifilament yarn, the multifilament yarn is deformed to some extent in its longitudinal direction and is bent, so that the yarn is shortened in the absence of tensile stress. In the case of the application of tensile stress, the individual deformed multifilament yarns can then be straightened out again to such an extent that good elongation properties are obtained with the usual and also preferred use of inelastic thermoplastics and, to a limited extent, also elastic recovery properties are obtained in the longitudinal direction of the deformed multifilament yarns.

Multifilament yarns with a fineness typically between 49dtex and 190dtex can also be considered for the first and second knitted fabric layers. The multifilament yarn can have, for example, 24 filaments, but other yarn constructions are also conceivable, including multifilament yarns based on microfibers.

The spacer yarns are usually composed of monofilament yarns, the fineness of which can be adjusted in particular according to the desired compressive strengthTo select.

Within the scope of the invention, the spacer knitted fabric according to the invention can be used very widely, wherein use in particular in motor vehicles is particularly preferred.

As described above, properties are obtained which correspond in part to the properties of the spacer knit in DE 102016125881B 3, wherein a substantial improvement in the air permeability in the thickness direction is achieved by the openings in the two knit layers each consisting of a plurality of stitches. In other words, particular advantages are achieved in particular when such an air passage in the thickness direction is provided in the region of the seat or of an interior trim part of the motor vehicle.

It should be pointed out here that the spacer knit according to the invention can also be used very flexibly for different composite components or differently shaped composite components. Firstly, the spacer knit is very well suited to providing bends and/or arcs on upholstery or similar composite components in line with DE 102016126881B 3 without excessively deforming or wrinkling a covering made of, for example, leather, synthetic leather or textile, which is carried by the spacer knit. That is, since such a large arc or rounding should be provided, the spacer knit with the second knitted fabric layer which is only less extensible is attached to the respective covering and decorative layer. It is also particularly advantageous here if the spacer knit according to one embodiment of the invention has a relatively low flexural rigidity, although it is only slightly extensible on the second knitted fabric layer.

The small bending stiffness of the second knitted fabric layer can be achieved by a first inlay pattern of the first yarn system and a second inlay pattern of the second yarn system. If, according to the first inlay yarn pattern, the individual yarns in the adjusted pillar inlay extend along only one respective course, it is possible to easily bend the individual courses in the transverse direction towards each other, but at the same time avoid excessive stretching or shrinking of the second yarn system in the transverse direction. A small bending stiffness in the production direction (knitting direction) is achieved by: in the case of the first yarn system, the chaining loops are omitted equidistantly in such a way that: where the thread is guided to a predetermined length without forming loops.

In the case of the bending of the spacer knit or of the composite material formed by the spacer knit, completely different properties are obtained within the scope of the described embodiments than in the case of a uniform layer material. In the case of a uniform layer material, for example a thick plastic film, the neutral fibers are generally in the center of the thickness when bent, whereas in the case of the spacer knit according to the invention the neutral fibers (i.e. fibers which do not undergo significant stretching and compression) are on the second knitted fabric layer when bent. Starting from this, the first knitted fabric layer is provided with the extensions and the pressing required for bending or bending.

According to the composite component described above, the second knitted fabric layer is arranged in the direction of the covering and decorative layer and is preferably directly connected to the covering and decorative layer. Due to the small extensibility of the second knitted fabric layer, the cover and the decorative layer can be protected against undesired wrinkling in the case of large arcs. However, it is also known in the automotive industry to three-dimensionally form the seat surface and backrest of a vehicle seat or other trim parts by means of a trim seam, so that, in particular, a good deformability and also a large extensibility are expediently provided below the respective covering and trim layer. Surprisingly, the spacer knit according to the invention is also particularly suitable for such applications if the layer of the knit having greater extensibility is oriented towards the covering and decorative layer.

Surprisingly, due to the exactly opposite arrangement compared to the previously described construction variant, a particularly good, relatively small-sized three-dimensional construction variant of the covering and decorative layer can be achieved by compressing the spacer knit on the compressed region.

The spacer knit is expediently compressed in the compression region by the connection between the cover and the decorative layer and the second knit layer. In this case, according to a particularly preferred embodiment of the invention, the covering and decorative layer can be stitched to the spacer knit (in the case of the second knitted fabric layer) in the compressed region. At the seam, the covering and the decorative layer are pulled in the direction of the second knitted fabric layer with at least partial compression of the spacer knit, so that a recess is formed there, starting from the initially flat structure. The spacer knit is then uncompressed or at least less compressed between adjacent compressed regions, so that raised regions are obtained in relation to the compressed regions in the covering and decorative layer.

The composite component can thus be provided with a particularly attractive structuring.

The structured portion can also help to improve ventilation of the occupant, for example in the case of use in a vehicle seat. A certain air transport along the compression region is already possible by the three-dimensional structuring. However, it is particularly preferred to be able to combine the composite component with active ventilation of an air-conditioned seat.

The compressed regions can be stitched or otherwise connected to form a pattern selected from the group consisting of a ribbed pattern, a rectangular pattern, a diamond pattern, and a triangular pattern. The triangular pattern is also called a diamond pattern according to the specific configuration. The illustrated pattern is merely exemplary, wherein, of course, curved, circular or irregular patterns and curves are also conceivable. It is of course also possible to combine different patterns locally with one another or to merge them into one another.

For example, if, in the case of a rib pattern, adjacent compressed regions and in particular seams do not intersect, the spacing between the respective centers of adjacent compressed regions or adjacent compressed regions can typically be between 15mm and 100mm, in particular between 20mm and 70 mm.

In the compression region, i.e. for example at the seam, the spacer knit is at least partially compressed. Typically, the spacer knit is compressed to 70% or less, in particular 50% or less, of the thickness of the spacer knit in the uncompressed state. Particularly preferably, the spacer knit is completely or almost completely compressed, so that only the thickness of the two knit layers with the spacer thread pressed between them is then retained. Here, the spacer knit is compressed, i.e. pressed, in the compressed region to 40% or less or 20% or less of the thickness in the uncompressed state, for example.

Even if the spacer knit and the cover and the decorative layer are connected to one another in the compressed region, for example by means of yarns, i.e. in particular sewn seams, an interlocking connection can additionally be provided between the cover and the decorative layer and the first knitted fabric layer, in particular by means of an adhesive. This adhesive bond serves for additional fixing and also makes the manufacturing process easier.

As already explained at the outset, the covering and decorative layer can preferably be made of leather or synthetic leather. However, depending on the application, other materials, such as decorative films or textiles, are also conceivable in principle.

As mentioned previously, the spacer knit is typically between 2mm and 20mm thick, where these data are of course in the uncompressed state. The thickness of the spacer knit is also approximately predetermined, to what extent the covering and the decorative layer can be three-dimensionally patterned by compression of the spacer knit.

As already explained above, the composite component can be provided for a vehicle seat or interior trim part or can form a seat support or interior trim part. That is to say, for example, if the composite component is provided for a vehicle seat, a pressure-elastic substructure, for example, a further spacer knit with a greater thickness, is usually connected to the second knitted fabric layer. It is therefore known that fluid distribution can be achieved in vehicle seats by means of spacer fabrics. By means of a corresponding substructure, for example a further spacer knit, air distribution can then also be achieved in the area, so that the additional spacer knit is not influenced by the compressed region and therefore does not hinder the air distribution. The spacer knit described above together with the covering and decorative layer connected to the first knit layer is then provided essentially for the passage of air in the thickness direction, wherein, in particular, an open structure with openings in the two knit layers is particularly advantageous here.

If the composite component is provided, for example, for a vehicle seat or a seat support or a seat surface forming a vehicle seat, the pressure-elastic substructure can also have a ventilation device or be connected to a ventilation device in a particularly advantageous manner.

In principle, however, other regions of a motor vehicle, the area of furniture, the seating area of a chair or the like can also be equipped with the composite component according to the invention. In this case, the second knitted fabric layer is then, for example, connected to a carrier, in particular a dimensionally stable carrier.

The seams can extend straight and parallel to each other. Alternatively, the ribs can also be formed or formed by seams which are not completely straight and extend, for example, in a wavy or zigzag manner.

Conversely, if the faces are separated due to the compressed area, the faces can typically have a width of 3cm²To 100cm²In between, especially at 8cm²To 50cm²The dimension in between. Here, the data of the surface is also relative to the center of each compressed area, which can be formed, for example, by a seam. The faces of the individual segments illustrated relate in particular to a rectangular pattern, a diamond pattern or a triangular pattern.

The particularly good formability of the spacer knit can be traced back to different aspects. First, the planar first knitted fabric layer facing the covering and decorative layer is particularly susceptible to deformation due to its good extensibility. That is, if the spacer knit is pressed there with the compressed regions being created, the force distribution is hardly along the plane of the first knit layer due to the good extensibility. In other words, the covering and the decorative layer can be pressed into the planar first knitted fabric layer very well.

In the case of the spacer knit, the second knit layer, which is flat and which is opposite the decorative layer, has a lower and preferably significantly lower extensibility. The tensile force exerted on the second knitted fabric layer in the compressed area, in particular by the seam, can be distributed over a larger area on the basis of said small extensibility.

The planar first knit layer and the covering and decorative layer arranged thereon also extend arcuately in cross section between two adjacent compression regions. Due to the restoring force in the compressed region, a tensile force is thereby also exerted on the second knitted fabric layer, which tensile force acts in the plane of the second knitted fabric layer. However, the tensile forces can be absorbed because the second knitted fabric layer has a smaller extension and in particular a significantly smaller extension than the first knitted fabric layer. In the case of a composite component, the covering extending arcuately in cross section between two adjacent compressed regions can thus be held or spread apart from the decorative layer to some extent.

Due to the second, less stretchable fabric layer, in particular, the spacer knit alone is sufficient to hold the elastically supported covering and decorative layer in the desired three-dimensionally structured shape. As a result, no additional tensile layer made of fabric or the like is required, which is particularly advantageous with regard to a construction which is as simple as possible and with regard to good air permeability.

In the case of the composite component according to the invention, it is advantageous, but not mandatory, to form corresponding openings in the two knitted fabric layers. Thus, spacer knits, which are also known, for example, from DE 102016125881B 3, are suitable in principle for forming the composite component according to the invention. In contrast to the composite materials known from this prior art, however, the spacer knit can then be arranged exactly the opposite way, so that according to the invention the knit layer with greater extensibility (referred to as the first knit layer within the scope of the invention) faces the covering and decorative layer and is preferably connected directly to the covering and decorative layer.

In a variant of the composite component according to the invention, it is provided that the second knitted fabric layer is formed at least from a first yarn system with a first inlay pattern and a second yarn system with a second inlay pattern, wherein the adjusted pillar inlay is provided as the first inlay pattern, in which case the yarns of the first yarn system form pillar stitches in an alternating sequence in the production direction and are guided without forming stitches and the yarns of the second yarn system are respectively guided on at least two adjacent stitch lines extending in the knitting direction.

With respect to this further construction possibility of the spacer knit, reference is made explicitly to the disclosure of DE 102016125881B 3.

Drawings

The invention is elucidated below on the basis of the accompanying drawings which show only one embodiment.

The attached drawings are as follows:

fig. 1 shows a composite assembly with a spacer knit and a cover and a decorative layer in a perspective sectional view, wherein the spacer knit and the cover and the decorative layer are stitched to one another,

figure 2 shows only the covering and decorative layers and the spacer knit before and after sewing in cross-section,

fig. 3 shows an assembly according to fig. 1, with an additional spacer knit as an air distribution layer,

figure 4 shows a first layer of knit fabric of the spacer knit,

figure 5 shows a second knit layer of the spacer knit,

figure 6 shows the inlay yarn pattern of the first yarn system for the second knitted fabric layer,

figure 7 shows an inlay pattern of a second yarn system with a first sub-yarn system and a second sub-yarn system for a second knitted fabric layer,

fig. 8a, 8b show an alternative embodiment of the composite component according to fig. 1.

Detailed Description

Fig. 1 shows a composite component which forms the uppermost layer of a vehicle seat, for example a passenger car seat. The composite component comprises a spacer knit 1, to which, as is usual, a production direction P and a transverse direction Q perpendicular thereto can be assigned. The construction of the spacer knit 1 is explained further below with reference to the production direction P and the transverse direction Q. The production direction P is also referred to as knitting direction or longitudinal direction on the basis of the manufacturing process.

The spacer knit fabric 1 has a planar first knit fabric layer 2, a planar second knit fabric layer 3, and spacer yarns 4 connecting the knit fabric layers 2, 3. In the case of the two planar knitted fabric layers 2, 3, a wale can be arranged in the production direction P and a course can be arranged in the transverse direction Q. During the knitting process, the stitches of the course are simultaneously formed by means of the assigned guide bar (legescheien), wherein the individual threads extend in the production direction P with their respectively assigned knitting pattern, i.e. optionally offset between the individual courses.

The spacer thread 4 connects the two knitted fabric layers 2, 3 and ensures the pressure-elastic recovery behavior of the spacer knit 1 when compressed in the thickness direction. The monofilament yarns are preferably provided for the spacer yarns 4 in order to achieve good elastic properties. The compressive strength can be determined by the yarn material, the density and the thickness of the spacer yarn 4.

According to fig. 1, a covering and decorative layer 5 is arranged on the first knitted fabric layer 2, wherein the covering and decorative layer is particularly preferably leather or artificial leather. In principle, however, film materials, textiles or similar materials are also conceivable. In the case of the covering and decorative layer 5 shown in fig. 1, which is made of leather or synthetic leather, perforations 6 are provided in order to be able to realize a ventilation function, which will be explained in more detail below.

In order to achieve a particularly high-quality design of the composite component, the spacer knit 1 has compressed regions 7, on which the spacer knit 1 is permanently at least partially compressed in order to structure the covering with the decorative layer 5. In the compressed region 7, the covering and decorative layer 5 and the spacer knitted fabric 1 (in the case of the second knitted fabric layer 3) are sewn together by means of corresponding decorative threads 8, so that a connecting portion 9 is formed between the covering and decorative layer 5 and the second knitted fabric layer 3 by means of the decorative threads 8.

It can also be seen from fig. 1 that in the compressed region 7 the spacer knit 1 is pressed to less than 50% of its thickness in the uncompressed state.

In the embodiment according to fig. 1, the compression regions 7 extend parallel to one another, so that a ribbed pattern results. The spacing of adjacent compression regions 7 in respect of the respective centers can in this case typically be between 15mm and 100 mm.

Further possible patterns of the compressed areas will be shown below, wherein of course very different types of patterns and combinations are contemplated herein. In particular, the seat surface can be designed according to technical requirements and aesthetic requirements by means of different patterns or combinations of pattern sections.

According to fig. 1, the spacer knit 1 is pressed in at the respective compression region 7 on the first knitted fabric layer 2, while the second knitted fabric layer 3 lies in one plane. In this connection, even if fig. 1 is idealized in its schematic representation, this asymmetrical characteristic is the subject of the invention and also results in a clear and permanent appearance of the three-dimensional design of the overlay and decorative layer 5.

This feature is achieved within the scope of the invention by: the first knitted fabric layer 2 facing the covering and decoration layer 5 has a greater extensibility in the production direction P and in the transverse direction Q than the second knitted fabric layer 3. That is to say, if the cover is pulled in the direction of the second knitted fabric layer 3 at the connection 9 of the decorative yarns 8 with the decorative layer 5 on the compressed region 7, the first knitted fabric layer 2 may be easily deformed there and in particular also extended, whereas, on account of the higher strength or the lower extensibility of the second knitted fabric layer 3, a smaller deformation occurs there.

The restoring force produced by the spacer threads 4 straightens the cover and decorative layer 5 between the compressed regions 7, as a result of which a tensile load is also produced on the second knitted fabric layer 3 in the plane. This tension can be absorbed due to the small extensibility of the second knitted fabric layer 3. Due to the different elongation properties and in particular the low extensibility of the second knitted fabric layer 3, the covering and the decorative layer 5 can be "opened" to some extent by the restoring force of the entire spacer knit 1.

It should be considered that: the term extensibility in the sense of the present invention means an elongation at a predetermined tensile force which does not cause damage to the spacer knit 1 and in particular to the two knit layers 2, 3 and preferably causes a significant reversible change.

The extensibility in the production direction P and in the transverse direction Q can thus be determined, for example, according to DIN EN ISO 13934-1 at a tensile force of 25N. For this test, strips of 50mm width can be cut out of the spacer knit and then an initial length is first marked on the spacer knit 1 and subsequently arranged to be sandwiched in the respective test device. In order to be able to test the two flat knitted fabric layers 2, 3 separately, the spacer thread 4 can then be cut by a cut which is guided parallel to the knitted fabric layers 2, 3. In this case, the influence of the remaining part of the spacer thread 4 remaining between the two flat knitted fabric layers 2, 3 is ignored and plays virtually only a secondary role in the extensibility. The pattern thus formed, i.e. the strip extending in the production direction P or the transverse direction Q depending on the test, is then subjected to a tensile force of 25N, and the increased length is then determined in%. Here, it is generally observed within the scope of the invention that: the elongation of the planar first knitted fabric layer is significantly greater than the elongation of the planar second knitted fabric layer. A ratio of at least 2: 1, but can easily reach 3: 1. 5: 1. 7: 1 or even 10: 1 or even higher.

Thus, for example, the elongation of the planar first knitted fabric layer 2 determined in the manner described with a tensile force of 25N is between 25% and 60% for the production direction P and the transverse direction Q. This good extensibility ensures that the first knitted fabric layer 2 can be easily pressed in at the connecting portion 9. In particular, due to the good extensibility, a significant force distribution hardly occurs along the first layer of knitted fabric 2.

The second flat knitted fabric layer 3 has a significantly lower elongation in the production direction P and in the transverse direction Q, under a tensile force of 25N and a test according to DIN EN ISO 13934-1. The elongation can be, for example, between 1.5% and 10%, in particular between 2% and 7%. This low elongation ensures that the second knitted fabric layer 3, as shown in fig. 1, is only slightly deformed and the covering and decorative layer 5 can be opened.

It is finally also shown in fig. 1 that the cover and the decorative layer 5 can be connected to the first knitted fabric layer 2 by a cohesive connection, in particular by an adhesive 10, which also makes the production process easier.

The aforementioned properties of the spacer knit 1 can also be seen in fig. 2, which shows the composite assembly only in a sectional view before and after the stitching.

The covering and the decorative layer 5 as well as the spacer knit 1 are substantially flat before the corresponding connecting portions 9 are produced on the compressed regions 7 by the decorative yarns 8. If the compressed regions 7 are then produced at a distance L from one another with respect to the respective centers, this length L is maintained on the second knitted fabric layer 3, while the first knitted fabric layer 2 can be lengthened arcuately due to its good extensibility.

Means for creating different stretch characteristics in the first and second knit fabric layers 2, 3 will be further described below.

Fig. 3 shows firstly a development of the composite assembly, in which the cover and decorative layer 5 are arranged on the additional air distribution layer 11 together with the spacer knit 1. The air distribution layer 11 can also consist of a further spacer knit, wherein the air distribution layer 11 is provided for distributing cooling air in said plane. For this purpose, the air distribution layer 11 is connected to a not shown ventilation device, for example a blower.

Air for cooling and temperature control for the user can then be blown out through the spacer knit 1 and the perforations 6 covering the decorative layer 5. In this case, the compressed region 7 can also be particularly advantageous in terms of user comfort, since the ribs formed in this way can circulate or discharge the blown air. That is, in this context, very good air permeability in the thickness direction is also advantageous for the spacer knitted fabric 1.

Fig. 4 exemplarily shows a construction scheme with a first layer of knitted fabric 2, which has good extensibility. The first knitted fabric layer 2 has a mesh pattern (Filetmuster) so that the first knitted fabric layer 2 has openings 12 respectively formed by a plurality of stitches. The eyelet inlay (filtleggun) is usually formed by means of two guide bars, wherein a good extensibility of the first layer of knitting 2 is also achieved by the openings 12.

In order to improve these properties still further, it is also possible to provide the first knitted fabric layer 2 with a relatively small yarn stretch during knitting.

Furthermore, the first knitted fabric layer 2 can also be composed of a deformed multifilament yarn which is not only particularly flexible, but which, based on the deformed structure, can also be reversibly extended to some extent in its longitudinal direction. This is also particularly suitable if the first knitted fabric layer 2 and preferably the entire spacer knit 1 are made of a non-elastic thermoplastic polymer, such as polyester, polyamide or polyolefin.

Fig. 5 shows a view of the second knitted fabric layer 3, which second knitted fabric layer 3 also has openings 12'. Even if fig. 4 and 5 are not to scale with respect to each other, it can be seen already in the case of a comparison of the stitch sizes that the openings 12' of the second fabric layer 3 in this embodiment are significantly smaller than the openings 12 of the first fabric layer 2.

It can already be seen in fig. 5 that the second knitted fabric layer 3 has a lattice structure in which case the yarns extending in the production direction P and in the transverse direction Q are less extensible than in the case of the first knitted fabric layer 2. This can be attributed in particular to the provision of a special knitting pattern for the second knitted fabric layer 3. Here, what is essential for a small elongation in the production direction P is: according to fig. 6, the second knitted fabric layer 3 has a first yarn system 13, which first yarn system 13 has a first inlay yarn pattern in the form of a modified pillar inlay yarn (fransleging). According to fig. 6, for the yarns of the first yarn system 13: which in the production direction P form the chaining coils 14 in an alternating sequence and are guided without forming a coil. According to fig. 6, for example, two pillar stitches (Fransenmaschen)14 are always formed alternately in the production direction P and then two stitches are left free, but the individual threads are here offset along the course of the stitch around the associated needle.

Furthermore, a second yarn system 15 having a first sub-yarn system 15a and a complementary second sub-yarn system 15b is provided for forming the second knitted fabric layer 3. Since the two partial yarn systems 15a, 15b themselves have a uniform, but complementary inlay pattern and together form a mesh inlay, it is within the scope of the invention to collectively refer to said partial yarn systems as second yarn system 15 even if a thread guide bar is provided for each partial yarn system 15a, 15b during knitting. The two partial yarn systems 15a, 15b can be formed, for example, with two guide bars with 1 full pass (Einzug) and 1 empty pass, respectively.

According to fig. 7, the yarns of the second yarn system 15 alternately constitute stitches of a pillar stitch 14' and a cloth inlay 16 along the production direction P. Specifically, two pillar stitches 14' alternate with two stitches of the cloth inlay 16. A small stretch ratio in the transverse direction Q is achieved by the loops of the cloth inlay yarn 16.

The sequence of the two loops 16 of the knitted-in stitch 14' and the cloth inlay is merely exemplary, wherein a larger number can also be provided in respect of the two loop types. The cloth inlay shown is also merely exemplary. Furthermore, loops selected from the group of warp knitted fabrics, satin weaves, velours and sateen can also be considered.

In order to achieve as low a stretch as possible overall, the second knitted fabric layer 3 with the first yarn system 13 and the second yarn system 15 is composed entirely of multifilament smooth yarns.

The thickness of the spacer knit 1 is typically between 2mm and 20mm, in particular between 3mm and 15 mm.

While fig. 1 shows an exemplary ribbed structure of the compression region 7, fig. 8a and 8b show further possible configurations, according to which a triangular pattern, also referred to as a diamond pattern, is shown there according to fig. 8 a. It has also been shown that sections of different geometries or at least different sizes can be formed by the compression region 7.

A diamond pattern is provided according to fig. 8 b.

In other words, unlike in the case of fig. 1, the decorative thread 8 forms a surface closed on itself in the compressed region 7 according to fig. 8a and 8 b. The base surface extending within each decorative yarn 8 can have a thickness of, for example, 3cm²And 100cm²The area in between.

Fig. 3 shows an exemplary embodiment in which the covering and decorative layer 5 and the spacer knit 1 are arranged on an air distribution layer 11, which forms a pressure-elastic substructure. Alternatively, however, it is also possible to connect a dimensionally stable carrier to the second knitted fabric layer 3, for example to form an instrument panel, a side panel or another type of interior trim of a motor vehicle. Of course, corresponding embodiments are also conceivable in other fields in which a high-quality appearance or an attractive design is desired.

In order to illustrate the particular advantages of the spacer knit 1 according to the invention, in the exemplary embodiment only a composite assembly is described by way of example, which has a compression region 7, wherein for this purpose the first relatively extensible knit layer 2 is connected to the covering and decorative layer 5, while the second knit layer 3, which has only a relatively small extensibility, is then able to spread apart the covering and decorative layer 5, which is supported elastically by the spacer yarns.

On the other hand, if a relatively large, uniformly curved surface is to be provided in the case of a composite component, the spacer knit 1 according to the invention is arranged exactly in the opposite manner to the layers of knitted fabric 2, 3, wherein the second layer of knitted fabric 3 with the lower extensibility then supports the covering and decorative layer 5. In terms of possible embodiments, reference is made to the example of DE 102016125881B 3, wherein the inventive embodiment of the spacer knit 1 also advantageously allows the ventilation function in the thickness direction (i.e. through the covering and decorative layer 5) to be provided in the case of a corresponding embodiment of the composite component. For this purpose, the covering and decorative layer 5 can also be provided with openings in the form of the aforementioned perforations 6, for example.