CN110891777B - 用于座椅用途的透气复合材料 - Google Patents

用于座椅用途的透气复合材料 Download PDF

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CN110891777B
CN110891777B CN201880045915.0A CN201880045915A CN110891777B CN 110891777 B CN110891777 B CN 110891777B CN 201880045915 A CN201880045915 A CN 201880045915A CN 110891777 B CN110891777 B CN 110891777B
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layer
seating
air flow
air
composite
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CN110891777A (zh
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D.M.布朗
J.D.科利
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Sage Vehicle Interior Ltd By Share Ltd
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Carpets (AREA)
  • Chair Legs, Seat Parts, And Backrests (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)

Abstract

通过结合穿孔表面层和背衬网格布形成复合材料以制备具有足够空气流动、撕裂强度和适用于座椅的美学特征的材料。

Description

用于座椅用途的透气复合材料
本申请基于35 U.S.C.Section 119(e)要求于2017年7月14日提交的美国临时专利申请序列号62/532,510的优先权，前述申请的全部内容通过引用在此并入。
背景技术
本发明大体上涉及穿孔的非织造绒面织物。更具体地，本发明涉及为这些材料赋予空气流动和美学特征。
目前，座椅用途市场提供包含孔眼(即，穿孔)的非织造绒面织物。当在加热和/或冷却座椅中使用时，这些绒面织物需要通过穿孔符合一定的空气流动规格。
穿孔或穿孔孔眼的尺寸和数量能够对空气流动产生积极或消极的影响。不仅是空气流动问题，穿孔特征还可限制对整体材料赋予美观性的能力。例如，装饰性网格布可包括在穿孔的背面以通过穿孔孔眼显示美观性(颜色、纹理等)。
然而，先前的努力已显示，当将装饰性网格布添加到穿孔材料背面时(无论穿孔数量和孔眼尺寸如何)，都会限制通过复合材料的空气流动。现有的穿孔表面和装饰性背衬材料的典型复合材料导致通过穿孔孔眼的透气性显著低于大多数标准，低达20CFM(立方英尺/分钟)。
因此，仍需要提供还能为穿孔材料赋予美学特征的透气性装饰性背衬网格布。
发明内容
以下代表本发明的简要概述以提供对本发明某些方面的基本理解。该概述不是本发明的广泛综述。其并非旨在确定本发明的关键或重要元素和/或描绘本发明的范围，而是以简化形式阐述本发明的理念，作为对将在下文中随后阐述的更详细描述的介绍。
本发明可包含用于座椅用途的材料。在本发明的一个实施方式中，该材料可包含背衬材料，所述背衬材料是透气和/或允许空气流动。在本发明的另一个实施方式中，该材料可为透气背衬网格布层，其被施加到穿孔层以形成用于座椅用途的复合材料。在又另一个实施方式中，本发明可包括如下的座椅复合材料：其包含被粘附到具有美学特征(诸如颜色)的透气背衬网格布上的穿孔的非织造绒面织物层。在本发明的仍然另一个实施方式中，复合材料可包含可通过粘合剂(诸如射流成网粘合剂、网，热激活粘合剂或粉末粘合剂)结合的多个透气层。
本发明还可包括一种制备材料的方法。在本发明的一个实施方式中，所述方法可包括以下步骤：提供透气表面层；提供透气背衬网格布层；和将表面层粘附到背衬网格布层以形成用于座椅用途的透气复合材料。
本发明还可包括用于座椅用途的座椅材料，所述座椅材料具有表面层以及具有美学特征的背衬层，所述表面层具有适于空气流动由其中通过的穿孔阵列，所述背衬层被粘附或层压到表面层以形成适于允许足够的空气流动由其中通过的用于座椅的透气复合材料。
本发明可进一步包括一种用于制备用于座椅用途的座椅材料的方法，包括提供具有适于空气流动从其中通过的穿孔阵列的表面层和提供通过穿孔可见的具有美学特征的背衬层，并且另外地，将背衬层粘附或层压到表面层以形成透气和适于允许足够的空气流动从其中通过的适合用于座椅用途的复合材料。
通过仔细阅读实施方式的详细描述，对于本发明相关的领域、技术和设备的技术人员而言，其他特征及其优点将是显而易见的。
附图说明
在附图中：
图1是根据本发明一个实施方式的并入装饰性背衬的复合材料的照片；
图2是根据本发明一个实施方式的并入装饰性背衬的复合材料的照片；
图3是根据本发明一个实施方式的穿孔材料的照片；
图4是根据本发明一个实施方式的穿孔材料的照片；
图5是根据本发明一个实施方式的透气背衬材料的照片；
图6是根据本发明一个实施方式的粘合剂网的照片；
图7是根据本发明一个实施方式的复合材料的照片；和
图8是根据本发明一个实施方式的复合材料的照片。
具体实施方式
本发明包括涉及座椅产品的材料、方法和系统。本发明的替代实施方式在图1-8中示出并在下文中更完整描述。
本发明可包含座椅材料。在本发明的一个实施方式中，座椅材料可为透气和/或允许空气流动。如这里所用，术语“透气”是指足够透气和/或允许足够体积的空气以合适的速率通过的用于座椅用途的材料。在本发明的一个实施方式中，如果座椅材料具有约115ft3/min/ft2(CFM)或更高的整体空气流动(如果多于一层则包含结合在一起的所有层)，则其为足够透气或“可呼吸的”。
在另一个实施方式中，座椅材料可具有合适的撕裂强度。例如，座椅材料可具有约50N(牛顿(kg·m/s2))或更高(适于单一材料)或者约100N或更高(适于复合材料)的梯形(“trap”)撕裂强度。
在本发明的另一个实施方式中，座椅材料可为透气背衬网格布层，所述透气背衬网格布层可被施加到透气表面层(诸如穿孔层)以形成用于座椅用途的透气复合材料。通过举例的方式，透气表面可具有约250CFM或更高的空气流动。在另一个实例中，透气表面层可为至少322CFM。
在又另一个实施方式中，本发明可包含座椅复合材料，所述座椅复合材料可具有粘附到透气背衬网格布的穿孔的非织造绒面织物层，所述透气背衬网格布可具有美学特征，诸如颜色。通过举例的方式，透气背衬网格布可具有约400CFM或更高的空气流动。在另一个实例中，透气表面层可为至少500CFM。
在本发明的仍然另一个实施方式中，透气复合材料层可通过粘合剂网、射流成网粘合剂、热激活粘合剂或粉末粘合剂来结合，对于整个复合材料，上述粘合剂中的任一种均需要保持足够的透气性。通过举例的方式，透气复合材料可为至少115CFM。在另一个实例中，透气复合材料可为至少125CFM。
本发明还可包括一种制备透气座椅材料的方法。在本发明的一个实施方式中，所述方法可包含以下步骤：提供透气表面层；提供透气背衬网格布层；和将表面层粘附到背衬网格布层以形成用于座椅用途的透气复合材料。
在一个示例性实施方式中，材料包含透气的装饰性网格布，所述透气的装饰性网格布可附接至其他层以形成整体的复合座椅材料。例如，当用合适的粘合剂附接至穿孔绒面织物时，穿孔复合材料可提供合适的空气流动并通过穿孔进一步展示诸如颜色的美学特征。
在另一个示例性实施方式中，本发明包含独特地能够产生美学效果的复合材料的优选平衡(穿孔绒面织物+粘合剂+特别构建的装饰性背衬材料)。
在又另一个实施方式中，本发明包括具有通过粘合剂层结合在一起的表面层和背衬层的复合材料。复合材料的表面层的一个实例可包括Sage Automotive,Inc.(Greenville,SC USA)的Nonwoven
Figure BDA0002360861720000041
汽车绒面织物产品，该产品是穿孔的(具有特定的孔眼尺寸、密度和孔眼数量)。可替代地，表面层可包含其他绒面织物和皮革。在该实施方式中，表面层可具有约200CFM或更高的空气流动。在另一个实例中，表面层可具有介于约200CFM和约400CFM之间的空气流动。
背衬层可以是透气的装饰性网格布，其可为针织材料。一个示例性实施方式可包含顶棚经编针织材料(headliner warp knit material)。可替代地，材料可为透气圆筒针织布。在仍然另一个替代方案中，透气的装饰性网格布具有一定的梯形撕裂强度以及空气流动。在又另一个实施方式中，网格布可具有机织或非织造的结构，但所述结构足够透气以适用于座椅用途。在该实施方式中，背衬层可具有约300CFM或更高的空气流动。在另一个实施方式中，背衬层可具有介于约300CFM和约600CFM之间的空气流动。
在另一个实施方式中，透气复合材料可以由粘附到背衬网格布层的穿孔材料的表面层形成，所述穿孔材料的表面层具有约322CFM的空气流动，所述背衬网格布层具有约563CFM的空气流动，以形成具有约142CFM的整体空气流动的复合材料。
本发明还可以包括一种独立材料的选项，所述独立材料被钉缝而不是附接到隔层或背衬层上。例如，这种材料可通过将隔层织物直接层压到没有背衬网格布的穿孔设计上来形成。在这种情况下，独立材料优选地具有足够的透气性以用于座椅用途。
在本发明的另一个实施方式中，复合材料可以包括具有穿孔的表面层和透气的装饰性背衬网格布，所述透气的装饰性网格布可以是针织材料，诸如圆筒针织构造，并且还可以允许通过穿孔显示出装饰性背衬网格布的颜色，同时保持所需的通过复合材料的空气流动。可通过替代方法来制备复合材料，包括通过将材料钉缝至或附接到隔层背衬或层压材料上以在需要满足空气流动/透气性规格的座椅用途中工作。
本发明的特征包括具有允许足够的空气流动或透气的孔眼的装饰性座椅材料。在利用高水平的穿孔尺寸、密度和数量的现有方法中，所得材料将不能满足撕裂强度的要求。在本发明中，可使用隔层(包括针织织物，诸如双针床针织隔层织物)或其他背衬来提高撕裂强度。
在仍然另一个实施方式中，本发明可以包括表面织物，诸如穿孔的非织造绒面织物；特殊构建的装饰性背衬网格布；以及将层结合在一起的粘合剂，以形成可用于座椅用途的透气的复合材料。
在一个示例性实施方式中，可使用背衬网格布，所述背衬网格布可以包括隔层，例如双针床编织隔层织物，所述隔层被附接或层压到加热和/或冷却的座椅材料上。在另一个实施方式中，可使用泡沫和网格布，条件是能实现足够的空气流动。
在又一个实施方式中，粘合剂可以是射流成网或粉末–分散层压。可替代地，可使用其他层压复合材料层而不会不利地影响空气流动的方式。在另一个实施方式中，如果使用粘合剂层或粘合剂组分，则可提供足够的粘合强度，以使结合的层不容易剥离或脱离开。
本发明的特征包括装饰性座椅材料，所述装饰性座椅材料具有允许足够的空气流动或透气的孔眼。在利用高水平穿孔尺寸、密度和数量的现有方法中，所得材料将不能满足撕裂强度要求。在本发明中，可使用隔层或背衬网格布(其可以包括针织织物，诸如双针床针织隔层织物)或者其他背衬来增强撕裂强度。这种增加的撕裂强度被具有有效孔隙率的材料平衡，以赋予复合材料足够的空气流动。透气性的重要组成部分可能是穿孔点数量的影响、粘合剂透气性和特殊构建的装饰网格布的透气性。
在图1-8中，显示了根据本发明的一个实施方式的示例性复合材料组成部分的照片。在一个示例性实施方式中，本发明可以包括座椅材料，所述座椅材料是表面层和装饰性背衬层的复合物，所述表面层和装饰性背衬层结合或粘附以形成用于座椅用途的透气层。在该示例性实施方式中，座椅材料可以包括至少115ft3/min/ft2的空气流动，并且其中梯形撕裂强度为大约100N或更大。
在另一个示例性实施方式中，本发明可包括复合材料，所述复合材料具有空气流动在约300至约600CFM范围内的背衬网格布层和空气流动在约200至约400CFM范围内的表面层，其与粘合剂结合使用以使复合材料的空气流动至少为115CFM或更高。
在仍然另一个示例性实施方式中，本发明包括一种复合材料，所述复合材料通过粘合剂将背衬网格布层与表面织物层结合。在一个实例中，背衬网格布大于400CFM，且表面层大于250CFM。
在仍然另一个示例性实施方式中，本发明包括一种复合材料，所述复合材料通过粘合剂将背衬网格布层与表面织物层结合。在一个实例中，背衬网格布大于500CFM，且表面层大于300CFM。
在仍然另一个示例性实施方式中，本发明包括一种复合材料，所述复合材料通过粘合剂将背衬网格布层与表面织物层结合。在一个实例中，背衬网格布为约563CFM，表面织物为约322CFM，并且当结合时，这些层形成约142CFM的复合材料。
在下文中显示了与市售材料相比较的本发明的替代实施方式的一个或多个实例的特征。
Figure BDA0002360861720000061
Figure BDA0002360861720000071
表1：替代穿孔表面层的透气性数据
Figure BDA0002360861720000081
表2：替代圆筒针织背衬网格布层的透气性和撕裂强度
Figure BDA0002360861720000082
Figure BDA0002360861720000091
Figure BDA0002360861720000101
表3：替代穿孔表面层的透气性和撕裂强度。
这些结果表明，选择合适的背衬层孔隙率并将该层与合适的表面层(诸如具有优选穿孔阵列和尺寸的表面层)组合，可影响复合材料的整体透气性和强度。本发明的透气性、梯形撕裂强度和断裂强度是平衡的，以实现透气的装饰性和功能性的座椅材料。
本发明还可以包括一种用于制备诸如本文所述的复合材料的方法。在本发明的一个实施方式中，可提供在复合材料的表面层上打孔的穿孔设备。也可提供粘合剂层压以组合各层。接下来，可形成穿孔的表面层。可形成背衬层。最后，可通过将穿孔表面层和背衬层与粘合剂组分结合来形成穿孔表面层和背衬层的复合物。在一个示例性实施方式中，粘合剂组分可以是热激活粘合剂、射流成网粘合剂、粉末层压或保持足够空气流动和粘合强度的另一种合适的粘合剂材料。
在本发明的另一个示例性实施方式中，工艺参数可以使得能够制备诸如本文所述的复合座椅材料。例如，某些参数可用于增强用于座椅的复合材料的耐磨性、可燃性、接缝强度、撕裂强度、拉伸强度。
相关领域的技术人员将从优选实施方式的前述描述中意识到，可以在不脱离由所附权利要求限定的本发明的精神和范围的情况下进行替换和修改。

Claims (14)

1.一种用于座椅用途的座椅材料，包括：
表面层，其具有适于空气流动由其中通过的穿孔阵列；
所述表面层具有座椅表面和与所述座椅表面相反的背部表面；
粘合剂层，其粘附至所述表面层的所述背部表面；
具有美学特征的透气网格布层；和
该透气网格布层被粘附或层压到所述粘合剂层以形成用于座椅用途的适于允许足够的空气流动由其中通过的透气复合材料，
从而所述透气网格布层的所述美学特征通过所述穿孔从所述表面层的所述座椅表面是可以看到的，
其中所述表面层是绒面织物、皮革或非织造绒面织物，所述透气复合材料具有115CFM或更高的空气流动，和所述透气复合材料具有100N或更大的梯形撕裂强度。
2.如权利要求1所述的座椅材料，其中所述表面层适于加热和冷却的空气从其中通过。
3.如权利要求1所述的座椅材料，其中所述透气复合材料具有200CFM或更高的空气流动。
4.如权利要求2所述的座椅材料，其中所述表面层具有200CFM至400CFM的空气流动。
5.如权利要求1所述的座椅材料，其中所述表面层具有250CFM或更高的空气流动。
6.如权利要求5所述的座椅材料，其中所述表面层具有至少300CFM的空气流动。
7.如权利要求1所述的座椅材料，其中所述网格布层具有300CFM或更高的空气流动。
8.如权利要求7所述的座椅材料，其中所述网格布层具有300CMF至600CFM的空气流动。
9.如权利要求7所述的座椅材料，其中所述透气网格布层具有400CFM或更高的空气流动。
10.如权利要求7所述的座椅材料，其中所述透气网格布层具有至少500CFM的空气流动。
11.如权利要求1所述的座椅材料，其中所述透气复合材料具有142CFM的空气流动。
12.如权利要求1所述的座椅材料，其中所述美学特征是颜色。
13.如权利要求1所述的座椅材料，其中所述透气复合材料具有100N或更高的撕裂强度。
14.一种制备用于座椅用途的座椅材料的方法，其包括以下步骤：
提供具有适于空气流动由其中通过的穿孔阵列的表面层，所述表面层具有座椅表面和与所述座椅表面相反的背部表面；
提供粘合剂层；
提供具有可通过所述穿孔看到的美学特征的透气网格布层；
将所述透气网格布层粘附或层压到所述粘合剂层；和
将所述表面层粘附或层压到所述粘合剂层以形成用于座椅用途的复合材料，所述复合材料是透气的，并且适于允许足够的空气流动由其中通过，且其中所述透气网格布层通过所述穿孔从所述表面层的所述座椅表面是可以看到的，
其中所述表面层是绒面织物、皮革或非织造绒面织物，所述透气复合材料具有115或更高的空气流动，和所述透气复合材料具有100N或更大的梯形撕裂强度。
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