Pile knit fabric for interior materials of vehicles, method of manufacturing the same and manufacturing machine of pile knit fabric

Abstract

A pile knit fabric for internal materials of vehicles may include a knit layer prepared by weaving ground yarns, on one surface thereof, and a pile layer prepared by interweaving pile yarns with ground yarn loops of the knit layer, on the other surface thereof and, thus, has excellent physical coupling force between the ground yarns and the pile yarns and has excellent abrasion resistance, scratch resistance and formability as well as soft tactility.

What is claimed is: 
     
         1 . A pile knit fabric for internal materials of vehicle, the pile knit fabric comprising:
 a knit layer formed of a plurality of ground yarns woven lengthwise and widthwise into loop shapes; and   a pile layer formed of a plurality of pile yarns interwoven with ground yarn loops of the knit layer,   wherein the knit layer is prepared by weaving the plurality of ground yarns to form a double-sided loop structure or a single-sided loop structure; and   wherein the pile layer is fixed to a surface of the knit layer and prepared by interlacing the plurality of pile yarns with the ground yarn loops of the knit layer.   
     
     
         2 . The pile knit fabric of  claim 1 , wherein the plurality of ground yarns or the plurality of pile yarns are formed of one or more selected from the group consisting of polyamide, polypropylene, polyethylene terephthalate (PET), wool and combination thereof. 
     
     
         3 . The pile knit fabric of  claim 1 , wherein a number of the ground yarn loops of the knit layer is 250-950 per meter in a horizontal direction thereof. 
     
     
         4 . The pile knit fabric of  claim 1 , wherein the plurality of ground yarns has fineness of 50-200 denier. 
     
     
         5 . The pile knit fabric of  claim 1 , wherein the knit layer has a thickness of 0.1-2 mm and a weight per area of 40-200 g/m 2 . 
     
     
         6 . The pile knit fabric of  claim 1 , wherein one strand of the plurality of pile yarns includes 10-140 strands of filaments, and the filaments have fineness of 3-25 denier. 
     
     
         7 . The pile knit fabric of  claim 1 , wherein the plurality of pile yarns has a length of 2-10 mm. 
     
     
         8 . The pile knit fabric of  claim 1 , wherein the pile layer has a thickness of 1-9 mm and a weight per area of 100-600 g/m 2 . 
     
     
         9 . The pile knit fabric of  claim 1 , wherein the pile knit fabric has a weight per area of 200-700 g/m 2 . 
     
     
         10 . A method of manufacturing a pile knit fabric for internal materials of vehicle, the method comprising:
 preparing a plurality of ground yarns and a plurality of pile yarns;   weaving the plurality of ground yarns into loop shapes to intersect each other lengthwise and widthwise;   producing a double woven fabric using a double Raschel method by interweaving the plurality of pile yarns with ground yarn loops;   producing pile knitted fabrics by cutting the plurality of pile yarns of the double woven fabric;   brushing the cut pile yarns of the pile knitted fabrics; and   performing heat treatment of the brushed pile knitted fabrics.   
     
     
         11 . The method of  claim 10 , wherein, in the producing the pile knitted fabrics, the plurality of pile yarns of the double woven fabric is cut to have a length of 2-10 mm. 
     
     
         12 . The method of  claim 10 , wherein, in the brushing the pile knitted fabrics, the cut pile knitted fabrics are brushed by rotating a brush at a rate of 400-800 revolutions per minute (RPM) and a speed of 4-10 m/min. 
     
     
         13 . The method of  claim 10 , wherein, in the performing heat treatment of the pile knitted fabrics, the heat treatment is performed at a temperature of 110-200° C. for 2-10 minutes. 
     
     
         14 . A manufacturing machine of a pile knit fabric for internal materials of vehicle, the machine comprising:
 a weaving unit configured to produce a double woven fabric by weaving a plurality of ground yarns into loop shapes to intersecteach other lengthwise and widthwise and connecting ground yarn loops by a plurality of pile yarns through vertical reciprocation;   fabric transfer rollers engaged to the double woven fabric and configured to transfer the double woven fabric produced by the weaving unit;   a cutting unit configured to produce pile knitted fabrics by cutting the plurality of pile yarns of the double woven fabric transferred from the fabric transfer rollers;   brushing units receiving the cut pile yarns of the pile knitted fabrics and configured to brush surfaces of the cut pile yarns of the pile knitted fabrics; and   a heat treatment unit configured to perform heat treatment of the brushed pile knitted fabrics.   
     
     
         15 . The manufacturing machine of  claim 14 , wherein the cutting unit includes:
 at least a knife blade configured to cut the double woven fabric;   at least a grinding stone selectively engaged to the at least a knife blade to grind the at least a knife blade;   driving pulleys engaged to the at least a knife blade and configured to position the at least a knife blade;   driving belts coupled to the driving pulleys and configured to rotate the driving pulleys; and   a fixing shaft fixed to the at least a knife blade.   
     
     
         16 . The manufacturing machine of  claim 14 , wherein the at least a grinding stone is configured to grind the at least a knife blade at a grinding angle of 45-55°. 
     
     
         17 . The manufacturing machine of  claim 14 , wherein each of the brushing units includes a cylinder and a brush coupled to the cylinder.