Toward on integrally-formed knitted fabrics used for automotive seat cover

Abstract

Knitting forming is an advantage and distinguishing feature of knitting technology. The development of three-dimensional (3D) shaped technology and equipment, making knitted fabrics gradually developed from clothing domain to the industrial field. The automotive industry is one of the biggest markets for industrial textiles. Recently, most car seat covers in domestic market are made by cutting-and-sewing process, while, integrally-formed car seat covers are greatly far from commercial products. Therefore, this paper describes four knitting techniques for producing 3D shaped fabrics, and studies the knitting process of two types of 3D shaped geometries derived from car seat models. In present study, three-dimensional cutting method is used to unfold the two shapes in different ways and two knitting directions of one cutting method for individual 3D geometry are selected to knit on a Stoll computerized knitting machine. A mathematical relationship between 3D geometry and 2D unfolded shaping is established. After the shaping of each part is calculated, the program is made by the Pattern Preparation Unit and the knitting process is completed. The influence of two shaping techniques on the mechanical properties of the fully-fashioned fabric is evaluated, and it is found that compared with transferring-stitches technique, partial-knitting technique has superior mechanical properties. This study provides guides and references for the integrated automotive seat covers.