US-12624479-B2 - Flooring woven fabric

Abstract

Disclosed herein, inter alia, is a flooring woven fabric. The flooring woven fabric includes a fabric layer including bulked continuous filaments (BCFs) having crimp and a polymer resin composition. The fabric layer includes a woven yarn of BCFs and the polymer resin composition is applied on the top portion of the fabric layer such that the polymer resin to form a coating layer. The polymer resin composition of the coating layer may penetrate between the BCFs and yarns made of BCFs. As such, the flooring woven fabric may have improved the wear resistance to strengthen the surface properties and positioning the coating layer to block the penetration of liquid contaminants at the same time, thereby improving the decontamination performance.

Inventors

• Hyun Dae Cho
• Mi Jung Yun
• Chang Hyeon Noh
• Hyun Joung JUN
• Hae Min Hwang

Assignees

• HYUNDAI MOTOR COMPANY
• KIA CORPORATION
• KOLONGLOTECH. INC

Dates

Publication Date

20260512

Application Date

20220921

Priority Date

20210924

Claims (10)

1. 1 . A flooring woven fabric comprising: a fabric layer comprising bulked continuous filaments (BCFs) having crimp; and a polymer resin composition penetrating the fabric layer and binding the plurality of the bulked continuous filaments (BCFs); wherein the polymer resin composition comprises: an amount of 30 to 50% by weight of an acrylate-based resin; an amount of 1 to 5% by weight of acrylic acid; an amount of 2 to 5% by weight of additives; and an amount of 40 to 65% by weight of water based on 100% by weight of the polymer resin composition, wherein the polymer resin composition has a viscosity of 1,000 to 6,000 mPa·S, wherein each of the bulked continuous filament (BCF) has a twisting number of 100 to 200 twists/m.
2. 2 . The flooring woven fabric of claim 1 , wherein the fabric layer comprises a woven yarn made of the bulked continuous filaments (BCFs).
3. 3 . The flooring woven fabric of claim 1 , wherein each of the bulked continuous filament (BCF) has a crimp rate of 5 to 30%.
4. 4 . The flooring woven fabric of claim 1 , wherein each of the bulked continuous filament (BCF) has a fineness of 10 to 50 Denier.
5. 5 . The flooring woven fabric of claim 1 , wherein the warp and weft of the fabric layer respectively have a weaving density of 10 to 50 counts/inch.
6. 6 . The flooring woven fabric of claim 1 , wherein the fabric layer has a weight of 400 to 1,000 g/m 2 .
7. 7 . The flooring woven fabric of claim 1 , wherein the polymer resin composition further comprises an amount of 1 to 10% by weight of an antifouling agent.
8. 8 . The flooring woven fabric of claim 1 , wherein the polymer resin composition has a weight of 80 to 150 g/m 2 .
9. 9 . The flooring woven fabric of claim 1 , wherein the acrylate-based resin has a glass transition temperature (Tg) of greater than about −60° C. to less than 30° C.
10. 10 . A vehicle comprising a flooring woven fabric of claim 1 .

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims under 35 U.S.C. § 119(a) the benefit of priority to Korean Patent Application No. 10-2021-0126262 filed on Sep. 24, 2021, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD The present invention relates to a flooring woven fabric preventing contamination while providing an exterior design pattern. BACKGROUND A tufted carpet of a tufting structure including a plurality of piles or a nonwoven carpet of needle punching have been mainly used as a conventional automotive flooring fabric. However, in the case of conventional flooring fabrics, there has been a problem in that solid foreign substances such as sand, etc. are interposed between piles or raised layers and remain, and fine dust is caused inside a vehicle since it is difficult to completely remove them even if they are physically brushed off. In the case of liquid contaminants, there has been a problem in that they are permeated into the inside of the piles and penetrated into the floor under the piles, causing mold or bacteria to occur. With a simple pile structure, there are limitations in the realization of design and pattern so that there has been a problem in that there is a limit to the improvement of merchantability in terms of appearance. SUMMARY In preferred aspects, provided is a flooring woven fabric that include: a fabric layer comprising a bulked continuous filaments (BCFs) having crimp; and a polymer resin composition penetrating the fabric layer and binding the bulked continuous filaments. The object of the present invention is not limited to the object mentioned above. The object of the present invention will become more apparent from the following description, and will be realized by means and combinations thereof described in the claims. In an aspect, provided is a flooring woven fabric that includes: a fabric layer including bulked continuous filaments (BCFs) having crimp; and a polymer resin composition penetrating the fabric layer and binding the bulked continuous filaments. The fabric layer may preferably include a woven yarn made of the bulked continuous filaments (BCFs). Each of the bulked continuous filament (BCF) may have a crimp rate of about 5 to 30%. Each of the bulked continuous filament (BCF) may have a fineness of about 10 to 50 deniers (D). Each of the bulked continuous filament (BCF) may have a twisting number of about 100 to 200 twists/m. The warp and weft of the fabric layer may respectively have a weaving density of about 10 to 50 counts/inch. The fabric layer may have a weight of about 400 to 1,000 g/m2. The polymer resin composition may comprise: an amount of about 30 to 50% by weight of an acrylate-based resin; an amount of about 1 to 5% by weight of acrylic acid; an amount of about 2 to 5% by weight of additives; and an amount of about 40 to 65% by weight of water based on 100% by weight of the total polymer resin composition. The polymer resin composition may further comprise an amount of about 1 to 10% by weight of an antifouling agent. The polymer resin composition may have a weight of about 80 to 150 g/m2. The acrylate-based resin may have a glass transition temperature (Tg) of greater than about −60° C. to less than about 30° C. The polymer resin composition may have a viscosity of about 1,000 to 6,000 mPa·S. In an aspect, provided is a vehicle interior material including the flooring woven fabric as described herein. Also provided is a vehicle including the flooring woven fabric as described herein. Other aspects of the invention are disclosed infra. The flooring woven fabric according to various exemplary embodiments of the present invention can provide an exterior design pattern and have excellent surface abrasion properties by including a fabric layer in which a yarn composed of a bulked continuous filament (BCF) having crimp properties is woven. Further, the flooring woven fabric according to various exemplary embodiments of the present invention may improve wear resistance by friction to strengthen the surface properties and positioning the coating layer to block the penetration of liquid contaminants at the same time, thereby improving the decontamination performance by coating a coating layer containing a polymer resin composition on the top portion of the fabric layer and allowing a polymer resin contained in the coating layer to penetrate between the yarns in the fabric layer to fix the yarns, thereby improving the bonding force. The effects of the present invention are not limited to the above-mentioned effects. It should be understood that the effects of the present invention include all effects that can be inferred from the following description. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a cross-sectional view of a flooring woven fabric according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION The above objects, other objects, features and advantages of the present invent