WO2023212337A1 - Tissu perméable à l'air - Google Patents

Tissu perméable à l'air Download PDF

Info

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
Application number
PCT/US2023/020431
Other languages
English (en)
Inventor
Karthik Arumugam
Jessica Gibby SULLIVAN
Brandon Ratcliffe
Mark R. KAPHENGST
Original Assignee
Tenowo Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tenowo Inc. filed Critical Tenowo Inc.
Publication of WO2023212337A1 publication Critical patent/WO2023212337A1/fr

Links

Classifications

    • 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.

Landscapes

  • 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

Un tissu à structure perméable non tissée est destiné à être utilisé dans la construction de sièges automobiles. Le tissu à structure perméable comprend 60 % à 99 % en poids d'une première fibre et la première fibre a une première masse et un premier point de fusion. La structure perméable comprend 1 à 40 % en poids d'une seconde fibre et la seconde fibre a un second point de fusion qui est inférieur au premier point de fusion. La première fibre et la seconde fibre sont enchevêtrées mécaniquement dans une première dimension et la première fibre et la seconde fibre sont enchevêtrées mécaniquement dans une seconde dimension qui est généralement perpendiculaire à la première dimension. La première masse est comprise entre environ 10 deniers et environ 30 deniers.
PCT/US2023/020431 2022-04-29 2023-04-28 Tissu perméable à l'air WO2023212337A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263336615P 2022-04-29 2022-04-29
US63/336,615 2022-04-29

Publications (1)

Publication Number Publication Date
WO2023212337A1 true WO2023212337A1 (fr) 2023-11-02

Family

ID=88519723

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2023/020431 WO2023212337A1 (fr) 2022-04-29 2023-04-28 Tissu perméable à l'air

Country Status (1)

Country Link
WO (1) WO2023212337A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
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

Patent Citations (2)

* Cited by examiner, † Cited by third party
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

Similar Documents

Publication Publication Date Title
US7591346B2 (en) Sound absorptive multilayer composite
US8727417B2 (en) Molded laying interior material for vehicle
EP1590170B1 (fr) Tapis tufte pour voiture possedant des proprietes acoustiques ameliorees
JP4394638B2 (ja) 自動車用成形敷設内装材
JP3613727B2 (ja) 成形性に優れた吸音材
US20040231914A1 (en) Low thickness sound absorptive multilayer composite
JP4001588B2 (ja) 自動車用成形敷設内装材
US20070254130A1 (en) Laminates with sound absorbing porperties
JP3883008B2 (ja) 発泡成形体補強材及び車両用座席
WO2012173104A1 (fr) Étoffe non tissée pour renforcer un article moulé en mousse et produit l'utilisant
EP1473706B1 (fr) Materiel de revetement de sol, moquette en coupon, et structure d'installation du materiel
WO2023212337A1 (fr) Tissu perméable à l'air
JP2000062061A (ja) 発泡成型用補強材基布
KR20190037024A (ko) 타공필름과 합성수지 파우더를 갖는 다층구조의 차량용 내장재 및 그 제조방법
JP6646267B1 (ja) 積層吸音材
TW201841755A (zh) 吸音多層裁剪部件及其製造方法及應用
US20220410525A1 (en) Layered sound-absorbing material
JP2004122545A (ja) 熱成形性芯材及びこれを用いた自動車用内装材
JP4117541B2 (ja) 発泡成形用補強材
JP4022568B2 (ja) 自動車用成形敷設内装材
JPS5913070Y2 (ja) 外面被覆用パツド
JP5624870B2 (ja) 発泡成形体および発泡成形体の製造方法
JP3079036B2 (ja) タフテッドカ−ペット用基布
JP3956197B2 (ja) 自動車用フロアカーペットの製造方法
JP3188598B2 (ja) 遮音構造体及びその製造方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 23797364

Country of ref document: EP

Kind code of ref document: A1