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 m ³ /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 m ³ /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 m ³ /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 m ³ /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 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.

[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 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.