WO2023212337A1 - Air permeable fabric - Google Patents
Air permeable fabric Download PDFInfo
- Publication number
- WO2023212337A1 WO2023212337A1 PCT/US2023/020431 US2023020431W WO2023212337A1 WO 2023212337 A1 WO2023212337 A1 WO 2023212337A1 US 2023020431 W US2023020431 W US 2023020431W WO 2023212337 A1 WO2023212337 A1 WO 2023212337A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fiber
- permeable structure
- structure fabric
- nonwoven
- fabric
- Prior art date
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 96
- 239000000835 fiber Substances 0.000 claims abstract description 88
- 238000002844 melting Methods 0.000 claims abstract description 11
- 230000008018 melting Effects 0.000 claims abstract description 11
- 238000010276 construction Methods 0.000 claims abstract description 5
- 229920000728 polyester Polymers 0.000 claims description 24
- 229920001634 Copolyester Polymers 0.000 claims description 7
- 239000012790 adhesive layer Substances 0.000 claims description 7
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 5
- 239000004626 polylactic acid Substances 0.000 claims description 5
- 238000004080 punching Methods 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 9
- 239000000203 mixture Substances 0.000 description 7
- 239000004745 nonwoven fabric Substances 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000004952 Polyamide Substances 0.000 description 3
- 229920002647 polyamide Polymers 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 239000004753 textile Substances 0.000 description 3
- 238000001816 cooling Methods 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 239000010985 leather Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
Definitions
- the present invention relates to the field of air permeable fabric, and more specifically to air permeable fabric used in the construction of automotive seats having comfort features where air flow through the air permeable fabric is important.
- Vehicle seating structures are conventionally covered in a fabric that has certain physical characteristics such as permeability (the capacity for air to pass through).
- permeability the capacity for air to pass through.
- a relatively high rate of airflow through the fabric and other features such as durability are important.
- Typical seating fabrics used in automotive interior seats include leather, vinyl, cloth based on Polyester, Nylon etc. and other synthetic compositions.
- Traditional automotive seating structures includes these A-side fabrics that are usually laminated or attached to a 3-6 mm thick pad made up of polyurethane foam. Such laminated structures are nearly impermeable or restrict airflow and thus are inconsistent with the advanced and desired comfort features. If such advanced features can be achieved with traditional fabric laminates, it is generally difficult to do that economically.
- the presently disclosed material/technology provides a nonwoven fabric that is durable and allows sufficient airflow through the fabric to provide comfortable seating.
- a nonwoven permeable structure fabric for use in the construction of automotive seats.
- the permeable structure fabric includes 60% - 99 % by weight of a first fiber and the first fiber has a first mass and a first melting point.
- the permeable structure includes 1 -40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point.
- the first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension.
- the first mass is between about 10 denier and about 30 denier.
- FIG. 1 shows a perspective view of one embodiment of the present invention
- FIG. 2 shows a cross-sectional view of the embodiment of the present invention shown in FIG. 1 taken along line 2-2;
- FIG. 3 shows a fabric laminated structure that includes a fabric according to the present invention in one of the layers
- FIG. 4 shows a cross-sectional view of the laminated structure shown in FIG. 3 taken along lines 4-4;
- FIG. 5 shows an intermediate product that exists during production of one embodiment of the present invention
- FIG. 6 shows one embodiment of the present invention that is produced from the intermediate product shown in FIG. 5.
- FIG. 1 shows a permeable structure fabric 10 according to the present invention.
- the structure fabric 10 is configured to support a facing fabric which comprises the contact surface of the vehicle seat.
- Structure fabric 10 as illustrated provide strength, durability and permeability to accommodate the requirements of the vehicle seat.
- the permeable structure fabric 10 defines a first surface 32 and a second surface 34.
- the first surface 32 and the second surface 34 bound a body 36 that is comprised of a plurality of entangled fibers.
- the permeable structure fabric 10 is a nonwoven fabric as is conventionally known. According to the illustrated embodiment, fibers are entangled by mechanical punching in two dimensions. It should be appreciated that, according to other embodiments, the fibers can be entangled by waterjets or some other method.
- the fibers are entangled in a first dimension which is perpendicular to the face of the fabric and the fibers are entangled in a second dimension that is generally perpendicular to the first dimension.
- the second dimension is also perpendicular to the linear, i.e., machine direction of the fabric, such that the second dimension extends between the two sides of the fabric.
- Entanglement of the first dimension extends through the body of the fabric from about one face to about the other face. Entanglement of the second dimension preferably does not extend through the body of the fabric, but lies generally near one face of the fabric.
- Fibers can be composed of a variety of different materials as is conventionally known. However, in the illustrated embodiment, the fibers are generally polyester and more specifically, polyester from recycled sources. Even more specifically the fibers are a blend of a first fiber and a second fiber wherein the second fiber has a lower melting point than the first fiber.
- the first fiber may be a polyester fiber and preferably the first fiber is of recycled polyester fibers.
- the second fiber can be low melt polyester such as lower melt bicomponent Copolyester/Polyester Sheath/Core fiber or another type of lower melting temperature fiber such as Polylactic acid Fiber (PLA) when compared to standard Polyester fiber.
- PPA Polylactic acid Fiber
- the lower melt fibers can be made from other known polymers such as polyamide, polypropylene, and polyethylene.
- the permeable structure fabric 10 is preferably 60 % to 100 % by weight of the first fiber with the balance being made up of the second fiber, more preferably 75 % to 95 % by weight of the first fiber with the balance being made up of the second fiber, and even more preferably 80 % to 90 % by weight of the first fiber with the balance being made up of the second fiber.
- the denier of the first fiber used in permeable structure fabric 10 is preferably between about 8 and about 30, more preferably between about 10 and about 25, and even more preferably between about 12 and about 20.
- Polyester fibers used could have a solid, hollow, or a sheath core construction.
- the polyester fibers used could have been made from virgin or recycled sources.
- the denier of the second fiber is between 2 and 18.
- the entangled fibers of the body 36 define a plurality of openings 38 through the body 36 such that surfaces 32 and 34 are fluidly connected.
- the openings 38 can be single direct passageways from a first end 42 defined in surface 32 and a second end 44 defined in surface 34. It should also be appreciated that the passageways can be interconnected, branched, and contain dead ends. It should be also appreciated that due to the nature of nonwoven fabrics, the passageways are comprised of interconnected voids and spaces and thus generally do not appear as defined tubes from one point to the other.
- a laminated structure 50 that is comprised of a layer of the permeable structure fabric 10 and a layer of a face fabric 70.
- the layer of the permeable structure fabric 10 and the layer of the face fabric 70 sandwich, and are bonded together by, an adhesive layer 80. Both the face fabric 70 and the adhesive layer 80 are air permeable 10.
- the adhesive layer 80 is permeable.
- the adhesive layer 80 is one of the following: a textile layer, a woven textile layer, a nonwoven textile layer, a permeable fdm, an array of dots or points of adhesive or a combination thereof.
- the adhesive layer is one of the following: an adhesive such as polyamide, copolyimide, copolyester, polyethlene, and a combination thereof.
- a plurality of openings 58 that are connected between the face fabric 70 and the adhesive layer 80 further connect with the openings 38 of the permeable structure fabric 10 to define openings 52 that extend through the laminated structure 50 from a first side 54 to a second side 56.
- the structural fabric 10 can be finished to a desired thickness using a process such as thermal compression.
- FIG. 6 shows one embodiment of the structure fabric 10 and FIG. 5 shows an intermediate fabric 14 that is created during the production of the structure fabric 10.
- the intermediate fabric 14 is a one pile structure created after the first-dimension entangling step described above and one step of entangling in the second dimensions near the surface 32 during which interlacing fibers 33 are defined.
- the intermediate fabric 14 includes the first face 32 as described above, with tufts 16 extending to one side thereof.
- the intermediate fabric 14 can be turned over and another second-dimension entangling step performed to define the interlacing fibers 35 near the surface 34.
- the structure fabric 10 as shown in FIG. 6 is defined.
- the finished structure fabric 10 includes a first surface 32, a second surface 34 and passageways 38 that fluidly connect the first surface 32 and the second surface 34.
- the present invention can be better understood by description of the operation thereof.
- the laminated structure 50 is positioned within a seat (not shown).
- the face fabric 70 is on the outside of the seat and positioned to come in contact with a seat occupant.
- the permeable structure fabric 10 layer of the laminated structure 50 is positioned inside of the seat.
- cool air is introduced on the permeable structure fabric 10 side of the laminated structure 50 such that air pressure is increased to force air through the laminated structure 56 and exits the face fabric 70 side of the laminated structure 50. In this manner, cool air can be introduced in close contact with the occupant thus cooling the occupant.
- the permeable structure fabric 10 is comprised of a fiber blend of 85% 16 denier Polyester fibers and 15% 4 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber.
- the target weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.0 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.169 - 0.208 m 3 /s (360 -440 CFM) as per ASTM D737.
- the permeable structure fabric 10 is comprised of a fiber blend of 85% 20 denier Polyester fibers and 15% 10 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber.
- the target weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.217 -0.250 m 3 /s (460 - 530) CFM as per ASTM D737.
- the permeable structure fabric 10 is comprised of a fiber blend of 85% 20 denier Polyester fibers and 15% 10 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber.
- the target weight of the permeable structure fabric 10 is 350 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.260 - 0.297 m 3 /s (550 - 630) CFM as per ASTM D737.
- the permeable structure fabric 10 is comprised of a fiber blend of 85% 16 denier Polyester fibers and 15% of 17 denier Polylactic acid Fiber (PLA)
- the weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.230 - 0.260 m 3 /s (487 - 550) CFM as per ASTM D737.
- a conventional nonwoven fabric produced in the same manner as the structure fabric 10 described above, i.e., a nonwoven fabric wherein the fibers are entangled by mechanical punching in two dimensions, with a fiber blend of 85% 6 denier Polyester and 0-15% 4 Denier low melt bicomponent fibers at a weight of 400 gsm and thickness of about 5.5 to about 7.0 mm the airflow was measured to be 0.132 - 0.137 m 3 /s (280-290) CFM using the same testing protocol. Which is a reduction of at least 100 CFM when compared to the example above according to a preferred embodiment of the present invention.
- the weight ranges of the fabric can be from 150 -500 gsm, more specifically between 250-450 gsm.
- the permeable structure fabric 10 was laminated with a permeable leather fabric with help of polyamide adhesive web. Alternatively a polyester adhesive web could also be used to aid lamination. Airflow through the laminated structure was measured to be about 0.069 m 3 /s (147 CFM) as per ASTM D737. Typical seating laminate requirements include a minimum of 0.052 m 3 /s (110 CFM) to accommodate advanced comfort function such as heat/cool features. [0036] A permeable structure fabric 10 having improved airflow qualities has been disclosed above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
A nonwoven permeable structure fabric for use in the construction of automotive seats. The permeable structure fabric includes 60% – 99 % by weight of a first fiber and the first fiber has a first mass and a first melting point. The permeable structure includes 1-40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point. The first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension. The first mass is between about 10 denier and about 30 denier.
Description
AIR PERMEABLE FABRIC
Technical Field and Background of the Invention
[0001] The present invention relates to the field of air permeable fabric, and more specifically to air permeable fabric used in the construction of automotive seats having comfort features where air flow through the air permeable fabric is important.
[0002] Advances in vehicle seating, such as automotive seats, include in-seat structures that have added comfort features such as heating/cooling. Vehicle seating structures are conventionally covered in a fabric that has certain physical characteristics such as permeability (the capacity for air to pass through). To accommodate the added comfort features, a relatively high rate of airflow through the fabric and other features such as durability are important.
[0003] However, physical characteristics of traditional seating fabric laminates are often not consistent with required characteristics of advanced vehicle seating. Typical seating fabrics used in automotive interior seats include leather, vinyl, cloth based on Polyester, Nylon etc. and other synthetic compositions. Traditional automotive seating structures includes these A-side fabrics that are usually laminated or attached to a 3-6 mm thick pad made up of polyurethane foam. Such laminated structures are nearly impermeable or restrict airflow and thus are inconsistent with the advanced and desired comfort features. If such advanced features can be achieved with traditional fabric laminates, it is generally difficult to do that economically.
[0004] Conventional solutions to improve air flow in traditional seating include the installation of spacer fabrics instead of traditional foam plush pads. One problem with such a solution is that such spacer fabrics are not adequately durable long term, complicated to use, and generally not cost effective.
Summary of the Invention
[0005] The presently disclosed material/technology provides a nonwoven fabric that is durable and allows sufficient airflow through the fabric to provide comfortable seating.
[0006] According to one aspect of the present invention, there is provided a nonwoven permeable structure fabric for use in the construction of automotive seats. The permeable structure fabric includes 60% - 99 % by weight of a first fiber and the first fiber has a first mass and a first melting point. The permeable structure includes 1 -40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point. The first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension. The first mass is between about 10 denier and about 30 denier.
Brief Description of the Drawings
[0007] The invention may be best understood by reference to the following description in conjunction with the accompanying drawing figures in which:
[0008] FIG. 1 shows a perspective view of one embodiment of the present invention;
[0009] FIG. 2 shows a cross-sectional view of the embodiment of the present invention shown in FIG. 1 taken along line 2-2;
[0010] FIG. 3 shows a fabric laminated structure that includes a fabric according to the present invention in one of the layers;
[0011] FIG. 4 shows a cross-sectional view of the laminated structure shown in FIG. 3 taken along lines 4-4; and
[0012] FIG. 5 shows an intermediate product that exists during production of one embodiment of the present invention; and
[0013] FIG. 6 shows one embodiment of the present invention that is produced from the intermediate product shown in FIG. 5.
Detailed Description of the Preferred Embodiment and Best Mode
[0014] Referring now specifically to the drawings, FIG. 1 shows a permeable structure fabric 10 according to the present invention. The structure fabric 10 is configured to support a facing fabric which comprises the contact surface of the vehicle seat. Structure fabric 10 as illustrated provide strength, durability and permeability to accommodate the requirements of the vehicle seat.
[0015] Referring now to FIGS. 1 and 2, the permeable structure fabric 10 defines a first surface 32 and a second surface 34. The first surface 32 and the second surface 34 bound a body 36 that is comprised of a plurality of entangled fibers. The permeable structure fabric 10 is a nonwoven fabric as is conventionally known. According to the illustrated embodiment, fibers are entangled by mechanical punching in two dimensions. It should be appreciated that, according to other embodiments, the fibers can be entangled by waterjets or some other method.
[0016] The fibers are entangled in a first dimension which is perpendicular to the face of the fabric and the fibers are entangled in a second dimension that is generally perpendicular to the first dimension. The second dimension is also perpendicular to the linear, i.e., machine direction of the fabric, such that the second dimension extends between the two sides of the fabric. Entanglement of the first dimension extends through the body of the fabric from about one face to about the other face. Entanglement of the second dimension preferably does not extend through the body of the fabric, but lies generally near one face of the fabric.
[0017] Fibers can be composed of a variety of different materials as is conventionally known. However, in the illustrated embodiment, the fibers are generally polyester and more specifically, polyester from recycled sources. Even more specifically the fibers are a blend of a first fiber and a second fiber wherein the second fiber has a lower melting point than
the first fiber. The first fiber may be a polyester fiber and preferably the first fiber is of recycled polyester fibers. The second fiber can be low melt polyester such as lower melt bicomponent Copolyester/Polyester Sheath/Core fiber or another type of lower melting temperature fiber such as Polylactic acid Fiber (PLA) when compared to standard Polyester fiber. It should be appreciated that, according to other embodiments, the lower melt fibers can be made from other known polymers such as polyamide, polypropylene, and polyethylene.
[0018] The permeable structure fabric 10 is preferably 60 % to 100 % by weight of the first fiber with the balance being made up of the second fiber, more preferably 75 % to 95 % by weight of the first fiber with the balance being made up of the second fiber, and even more preferably 80 % to 90 % by weight of the first fiber with the balance being made up of the second fiber.
[0019] The denier of the first fiber used in permeable structure fabric 10 is preferably between about 8 and about 30, more preferably between about 10 and about 25, and even more preferably between about 12 and about 20. Polyester fibers used could have a solid, hollow, or a sheath core construction. The polyester fibers used could have been made from virgin or recycled sources. The denier of the second fiber is between 2 and 18.
[0020] The entangled fibers of the body 36 define a plurality of openings 38 through the body 36 such that surfaces 32 and 34 are fluidly connected. The openings 38 can be single direct passageways from a first end 42 defined in surface 32 and a second end 44 defined in surface 34. It should also be appreciated that the passageways can be interconnected, branched, and contain dead ends. It should be also appreciated that due to the nature of nonwoven fabrics, the passageways are comprised of interconnected voids and spaces and thus generally do not appear as defined tubes from one point to the other.
[0021] Referring now to FIG. 3, there is shown a laminated structure 50 that is comprised of a layer of the permeable structure fabric 10 and a layer of a face fabric 70. The layer of the permeable structure fabric 10 and the layer of the face fabric 70 sandwich, and are
bonded together by, an adhesive layer 80. Both the face fabric 70 and the adhesive layer 80 are air permeable 10. The adhesive layer 80 is permeable. By way of example and not limitation, the adhesive layer 80 is one of the following: a textile layer, a woven textile layer, a nonwoven textile layer, a permeable fdm, an array of dots or points of adhesive or a combination thereof. By way of example and not limitation, the adhesive layer is one of the following: an adhesive such as polyamide, copolyimide, copolyester, polyethlene, and a combination thereof.
[0022] A plurality of openings 58 that are connected between the face fabric 70 and the adhesive layer 80 further connect with the openings 38 of the permeable structure fabric 10 to define openings 52 that extend through the laminated structure 50 from a first side 54 to a second side 56.
[0023] After initial production steps including the step, or steps, of entanglement; the structural fabric 10 can be finished to a desired thickness using a process such as thermal compression.
[0024] Referring now to FIGS. 5 and 6, FIG. 6 shows one embodiment of the structure fabric 10 and FIG. 5 shows an intermediate fabric 14 that is created during the production of the structure fabric 10. The intermediate fabric 14 is a one pile structure created after the first-dimension entangling step described above and one step of entangling in the second dimensions near the surface 32 during which interlacing fibers 33 are defined. The intermediate fabric 14 includes the first face 32 as described above, with tufts 16 extending to one side thereof. During production of the structure fabric 10 shown in FIG. 6, the intermediate fabric 14 can be turned over and another second-dimension entangling step performed to define the interlacing fibers 35 near the surface 34. In this manner, the structure fabric 10 as shown in FIG. 6 is defined. As indicated above, the finished structure fabric 10 includes a first surface 32, a second surface 34 and passageways 38 that fluidly connect the first surface 32 and the second surface 34.
[0025] The present invention can be better understood by description of the operation
thereof. The laminated structure 50 is positioned within a seat (not shown). The face fabric 70 is on the outside of the seat and positioned to come in contact with a seat occupant. The permeable structure fabric 10 layer of the laminated structure 50 is positioned inside of the seat. To cool the seat occupant, cool air is introduced on the permeable structure fabric 10 side of the laminated structure 50 such that air pressure is increased to force air through the laminated structure 56 and exits the face fabric 70 side of the laminated structure 50. In this manner, cool air can be introduced in close contact with the occupant thus cooling the occupant.
[0026] Example I
[0027] According to one example, the permeable structure fabric 10 is comprised of a fiber blend of 85% 16 denier Polyester fibers and 15% 4 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber. The target weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.0 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.169 - 0.208 m3/s (360 -440 CFM) as per ASTM D737.
[0028] Example II
[0029] According to another example, the permeable structure fabric 10 is comprised of a fiber blend of 85% 20 denier Polyester fibers and 15% 10 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber. The target weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.217 -0.250 m3/s (460 - 530) CFM as per ASTM D737.
[0030] Example III
[0031] According to another example, the permeable structure fabric 10 is comprised of a fiber blend of 85% 20 denier Polyester fibers and 15% 10 denier low melt bicomponent Copolyester/Polyester Sheath/Core fiber. The target weight of the permeable structure
fabric 10 is 350 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.260 - 0.297 m3/s (550 - 630) CFM as per ASTM D737.
[0032] Example IV
According to another example, the permeable structure fabric 10 is comprised of a fiber blend of 85% 16 denier Polyester fibers and 15% of 17 denier Polylactic acid Fiber (PLA) The weight of the permeable structure fabric 10 is 400 gsm and the thickness is between about 5.5 mm and about 7.5 mm. Airflow through the permeable structure fabric 10 was measured to be about 0.230 - 0.260 m3/s (487 - 550) CFM as per ASTM D737.
[0033] In comparison, a conventional nonwoven fabric produced in the same manner as the structure fabric 10 described above, i.e., a nonwoven fabric wherein the fibers are entangled by mechanical punching in two dimensions, with a fiber blend of 85% 6 denier Polyester and 0-15% 4 Denier low melt bicomponent fibers at a weight of 400 gsm and thickness of about 5.5 to about 7.0 mm the airflow was measured to be 0.132 - 0.137 m3/s (280-290) CFM using the same testing protocol. Which is a reduction of at least 100 CFM when compared to the example above according to a preferred embodiment of the present invention.
[0034] The weight ranges of the fabric can be from 150 -500 gsm, more specifically between 250-450 gsm.
[0035] According to another example, the permeable structure fabric 10 was laminated with a permeable leather fabric with help of polyamide adhesive web. Alternatively a polyester adhesive web could also be used to aid lamination. Airflow through the laminated structure was measured to be about 0.069 m3/s (147 CFM) as per ASTM D737. Typical seating laminate requirements include a minimum of 0.052 m3/s (110 CFM) to accommodate advanced comfort function such as heat/cool features.
[0036] A permeable structure fabric 10 having improved airflow qualities has been disclosed above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.
Claims
1. A nonwoven permeable structure fabric for use in the construction of automotive seats, the permeable structure fabric comprising:
60% - 99 % by weight of a first fiber and the first fiber has a first mass and a first melting point;
1-40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point; the first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension; and wherein the first mass is between about 10 denier and about 30 denier.
2. The nonwoven permeable structure fabric according to claim 1, wherein the fibers are entangled by mechanical punching.
3. The nonwoven permeable structure fabric according to claim 1, wherein the weight of the permeable structure fabric is 400 gsm.
4. The nonwoven permeable structure fabric according to claim 1, wherein the denier of the first fiber is between about 12 and 25.
5. The nonwoven permeable structure fabric according to claim 4, wherein the denier of the first fiber is about 16.
6. The nonwoven permeable structure fabric according to claim 4, wherein the denier of the first fiber is about 20.
7. The nonwoven permeable structure fabric according to either of claims 5 and 6, wherein the weight of the permeable structure fabric is between 250 gsm and 450 gsm.
8. The nonwoven permeable structure fabric according to either of claims 5 and 6, wherein the thickness of the permeable structure fabric is between about 5.0 mm and about 7.5 mm.
9. The nonwoven permeable structure fabric according to any of claims 1 through 8, wherein the first fiber is recycled polyester.
10. The nonwoven permeable structure fabric according to claim 9 wherein the first fiber comprises about 85% of the nonwoven permeable structure.
11. The nonwoven permeable structure fabric according to either of claims 9 and 10, wherein the second fiber is a lower melt polyester having a denier of about 4.
12. The nonwoven permeable structure fabric according to either of claims 9 and 10, wherein the second fiber is a lower melt polyester having a denier of about 10.
13. The nonwoven permeable structure fabric according to either of claims 9 and 10, wherein the second fiber is Polylactic acid Fiber.
14. The nonwoven permeable structure fabric according to either of claims 9 and 10, wherein the second fiber is a low melt bicomponent Copolyester/Polyester Sheath/Core fiber.
15. The nonwoven permeable structure fabric according to either of claims 9 and 10, wherein the second fiber is a low melt bicomponent Copolyester/Polyester Sheath/Core fiber having a denier of about 10.
16. The nonwoven permeable structure fabric according to claims 9 and 10, wherein the airflow is between about 0.179 m3/s and about 0-.297 m3/s.
17. The nonwoven permeable structure fabric according to claims 9 and 10, wherein the nonwoven permeable structure fabric is laminated to a face fabric with an adhesive layer sandwiched therebetween.
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US202263336615P | 2022-04-29 | 2022-04-29 | |
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Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10844528B2 (en) * | 2016-04-07 | 2020-11-24 | Sung Mo Jung | Anti-weed sheet |
US20210162702A1 (en) * | 2018-08-06 | 2021-06-03 | Zephyros, Inc. | Nonwoven composite for air flow applications |
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2023
- 2023-04-28 WO PCT/US2023/020431 patent/WO2023212337A1/en unknown
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10844528B2 (en) * | 2016-04-07 | 2020-11-24 | Sung Mo Jung | Anti-weed sheet |
US20210162702A1 (en) * | 2018-08-06 | 2021-06-03 | Zephyros, Inc. | Nonwoven composite for air flow applications |
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