Carbon fiber blended motor vehicle roof lining and motor vehicle seat cover containing the same

Abstract

The present invention provides a carbon fiber fabric, which comprises an interwoven fabric (2) of carbon fiber yarns (3) and polymer fiber yarns (4).

Description

Technical Field

[0001] The present invention relates to a fabric comprising carbon fibers, or a carbon fiber fabric. Background Art

[0002] Fabrics comprising carbon fiber warp and weft yarns are known in the prior art. Summary of the Invention

[0003] Object of the Invention

[0004] In order to meet the need for a fabric comprising carbon fibers and capable of elongating by at least 2-3% when subjected to traction compared to carbon fiber fabrics of the prior art, the applicant has developed a fabric comprising carbon fibers, which has an interwoven fabric of carbon fiber yarns and polymer fiber yarns.

[0005] Advantageously, the polymer fiber yarns woven with the carbon fiber yarns impart the required elongation ability to the fabric. Brief Description of the Drawings

[0006] Other features and advantages of the solution are more clearly apparent in the following exemplary and non-limiting description, with reference to the preferred embodiments of the carbon fiber fabric shown in the drawings, wherein:

[0007] Figure 1 A schematic view showing a part of the carbon fiber fabric according to the present specification;

[0008] Figure 2 Denotes Figure 1 A schematic cross-sectional view of the fabric;

[0009] Figure 3 Denotes Figure 1 Another schematic cross-sectional view of a part;

[0010] Figure 4 A schematic cross-sectional view showing a part of a motor vehicle roof made of the carbon fiber fabric according to the present specification;

[0011] Figure 5 A schematic perspective view of a motor vehicle including a roof made of the carbon fiber fabric according to the present specification;

[0012] Figure 6 Schematically shows Figure 5 the roof;

[0013] Figure 7 Denotes Figure 5 An enlarged detail of a first variant embodiment of the roof;

[0014] Figure 8 Denotes Figure 5 An enlarged detail of a second variant embodiment of the roof;

[0015] Figure 9 It represents Figure 5 an enlarged detail of a third variant embodiment of the ceiling;

[0016] Figure 10 represents Figure 5 an enlarged detail of a fourth variant embodiment of the ceiling;

[0017] Figure 11 represents Figure 6 a variant of the ceiling;

[0018] Figure 12 a partial cross-sectional schematic diagram of a motor vehicle seat upholstery cover made of a carbon fiber fabric according to this specification;

[0019] Figure 13 a schematic perspective view of a motor vehicle seat including an upholstery cover made of a carbon fiber fabric according to this specification;

[0020] Figure 14 represents Figure 13 an enlarged detail of a first variant embodiment of the seat;

[0021] Figure 15 represents Figure 13 an enlarged detail of a second variant embodiment of the seat;

[0022] Figure 16 represents Figure 13 an enlarged detail of a third variant embodiment of the seat;

[0023] Figure 17 represents Figure 13 an enlarged detail of a fourth variant embodiment of the seat. Detailed implementation mode

[0024] Reference numeral 1 represents the fabric according to this specification.

[0025] The fabric 1 includes carbon fiber yarns 3 and polymer fiber yarns 4, which are woven to form an interwoven fabric 2.

[0026] In other words, the fabric 1 has an interwoven fabric 2 of carbon fiber yarns 3 and polymer fiber yarns 4.

[0027] The carbon fiber yarns 3 have a linear density of 50 to 5000 g / km and include 1000 to 60000 filaments. Specifically, they are 3000 to 24000 filaments with a diameter between 5 and 10 microns.

[0028] More specifically, the interwoven fabric 2 includes the weft of the carbon fiber yarns 3 and the warp of the polymer fiber yarns 4.

[0029] Preferably, for the carbon fiber yarns 3 of the interwoven fabric 2, the number of filaments per yarn is between 1K and 60K (including the end values), in particular between 3K and 12K (including the end values).

[0030] In another embodiment, the interwoven fabric 2 includes weft yarns of polymer fiber yarns 4 and warp yarns of carbon fiber yarns 3.

[0031] Advantageously, the polymer fiber yarns 4 woven with the carbon fiber yarns impart the fabric 1 with elastic elongation ability, at least along the main extension direction of the yarns 4 themselves in the fabric 1.

[0032] When the polymer fiber yarns 4 form the warp of the fabric 1, the fabric 1 can be elastically elongated along the warp.

[0033] When the polymer fiber yarns 4 form the weft of the fabric 1, the fabric 1 can be elastically elongated along the weft.

[0034] The elongation of the fabric 1 in the direction of the polymer fiber yarns 4 is greater than the elongation of the fabric 1 in the direction of the carbon fiber yarns 3.

[0035] In an embodiment, if subjected to traction, the fabric 1 is stretched by at most 5% and at least 2% or 3%.

[0036] In an embodiment, the polymer fiber yarns 4 are polyester yarns.

[0037] Additionally, the polymer fiber yarns 4 are polypropylene yarns.

[0038] In another embodiment, the polymer fiber yarns 4 are aramid fiber yarns.

[0039] The polymer fiber yarns 4 woven with the carbon fiber yarns 3 can be used to manufacture a "hybrid" interwoven fabric 2, which can respond to traction loads by elongation, especially along the direction of load application.

[0040] Preferably, the interwoven fabric 2 is a "twill" interwoven fabric 2, especially "twill 2 / 1".

[0041] Preferably, the interwoven fabric 2 includes a pair of polymer fiber warp yarns 4 woven with a single carbon fiber yarn 3 (see Figure 2 ).

[0042] Regarding the bending strength according to the Bally test, mechanical laboratory tests show that the fabric 1 according to this specification can exceed 25,000 working cycles compared to 5,000 working cycles of existing carbon fiber fabrics.

[0043] In a preferred embodiment, the fabric 1 includes a protective layer 7 applied to the interwoven fabric 2, specifically to make the fabric 1 waterproof.

[0044] More specifically, the protective layer 7 includes a polymer-based solvent.

[0045] The protective layer 7 imparts a water impermeability of 2000 mm water column at 2 bar.

[0046] The protective layer 7 imparts scratch resistance of at least 20,000 working cycles.

[0047] The protective layer 7 is provided at least along one of the extending surfaces of the cross fabric 2, preferably the surface that is exposed to the external atmosphere under the use conditions.

[0048] In terms of its elongation characteristics, the fabric 1 can be used in numerous technical fields that require the light weight, mechanical strength, and traction elongation ability of carbon fiber.

[0049] For example, a nautical awning (not shown) may include the fabric 1 according to this specification.

[0050] In this context, with particular reference to Figure 4 and 5 , a roof lining 8 for a motor vehicle 100 having a main extension direction D is shown.

[0051] The roof lining or roof 8 is of the folding type, and the motor vehicle 100 is a convertible with a folding roof that can move between an open configuration (where the interior of the motor vehicle 100 is covered) and a closed or folded configuration (where the interior of the motor vehicle 100 is not covered) as shown in Figure 5 .

[0052] The roof lining 8 includes at least one rubber layer 9, preferably a butyl rubber layer 9, interposed between at least one first or inner layer 10 intended to face the interior of the motor vehicle 100 and a second or outer layer 11 intended to face the exterior of the motor vehicle 100.

[0053] The outer layer 11 includes the fabric 1, preferably coated with the protective layer 7.

[0054] For example, the first layer 10 of the roof lining 8 is made of a synthetic material, preferably an acrylic-based material.

[0055] In order to test the elongation rate of the fabric 1, a tensile test was carried out in accordance with DIN EN 13934-1.

[0056] The specimens for the tensile test included warp threads of carbon fiber yarn 3 and weft threads of polymer fiber yarn 4 (especially polyester).

[0057] The following figure shows the test results.

[0058]

[0059] The fabric 1 elongates by a maximum of 5% and at least 2% and 3%.

[0060] Reference Figure 6 It can be observed that the roof 8 preferably and schematically includes a main body portion 13 which is intended to at least partially define the top or roof of the motor vehicle 100, and at least a first side portion 14 and a second side portion 15, each defining at least a part of a respective flank of the motor vehicle 100.

[0061] The first side portion 14 and the second side portion 15 are arranged on opposite sides of the main body portion 13 along a second direction D.

[0062] The first side portion 14 and the second side portion 15 each have respective outer perimeters 23, 24 for contacting the body of the motor vehicle 100 when the roof 8 is in the closed state.

[0063] More specifically, the first side portion 14 and the main body portion 13 are joined along respective inner perimeters 14a and 13a, preferably by stitching, for example, the stitching can better fold the roof 8.

[0064] The second side portion 15 and the main body portion 13 are joined along respective inner perimeters 15a and 13b, preferably by stitching.

[0065] The main body portion 13 has a first inner perimeter 13a and a second inner perimeter 13b.

[0066] In a first embodiment, as Figure 7 shown, the inner perimeter 14a of the first side portion 14 and the first inner perimeter 13a of the main body portion 13 are joined in such a way that one side of the inner perimeter 14a of the first side portion 14 abuts against one side of the first inner perimeter 13a of the main body portion 13 to define a peak portion 16 extending along the length of the edges 13a, 14a.

[0067] This feature also applies to the inner perimeter 15a of the second side portion 15 and the second inner perimeter 13b of the main body portion 13.

[0068] In a second variant embodiment, a first seam 19 joins the face of the inner perimeter 14a of the first side portion 14 to the face of the first inner perimeter 13a of the main body portion 13 ( Figure 8 ).

[0069] This feature also applies to the inner perimeter 15a of the second side portion 15 and the second inner perimeter 13b of the main body portion 13.

[0070] The first seam 19 is transverse to the longitudinal extension direction of the peak portion 16.

[0071] In a third alternative variant embodiment ( Figure 9 ), a peak portion 16 provided with a first seam 19 is folded onto a part of the main body portion 13 or onto a part between the first side portion 14 and the second side portion 15.

[0072] These variants optionally include at least an adhesive material layer 20 placed on the peak portion 16 to hide it.

[0073] These variants also optionally include at least a second seam 21 that joins a portion of the adhesive material layer 20 to the main body portion 13.

[0074] The second seam 21 is parallel to the respective inner edges 13a, 13b of the main body portion 13, the first inner peripheral edge 13a, and the second inner peripheral edge 13b.

[0075] Another option is a second seam 21 that connects the respective portions of the adhesive material layer 20 to the first side portion 14.

[0076] The second seam 21 is parallel to the respective inner peripheral edge 14a of the first side portion 14.

[0077] Another option is a second seam 21 that joins the respective portions of the adhesive material layer 20 to the second side portion 15.

[0078] The second seam 21 is parallel to the respective inner peripheral edge 15a of the second side portion 15.

[0079] In the fourth embodiment, as Figure 8 shown, the flap 17 of the inner peripheral edge 14a of the first side portion 14 is preferably connected by a seam to the flap 18 of the first inner peripheral edge 13a of the main body portion 13, such that the main body portion 13 and the first side portion 14 overlap at least at the respective overlapping flaps 18, 17.

[0080] This feature also applies to the inner peripheral edge 15a of the second side portion 15 and the second inner peripheral edge 13b of the main body portion 13.

[0081] According to this description, the main body portion 13 of the ceiling 8 includes a fabric 1, or at least the main body portion 13 is preferably made of the fabric 1.

[0082] Advantageously, such a ceiling 8 has all the properties of the fabric 1, including elastic properties, at least at the main body portion 13.

[0083] Each of the first side portion 14 and the second side portion 15 includes a respective elastic element 22.

[0084] Advantageously, each elastic element 22 ensures the required folding direction during the opening / closing of the first side portion 14 and the second side portion 15 of the ceiling 8, thereby preventing the main body portion 13 from folding.

[0085] In fact, it has been found that folding the main body portion 13 when the ceiling 8 is opened or closed causes the formation of wrinkles, where the structure of the fabric 1 eventually wears out.

[0086] Referring to the first side portion 14, the elastic element 22 is disposed between the outer peripheral edge 23 and the inner peripheral edge 14a.

[0087] Preferably, the elastic element 22 extends from the outer peripheral edge 23 to the inner peripheral edge 14a.

[0088] Referring to the second side portion 15, the elastic element 22 is disposed between the outer peripheral edge 24 and the inner peripheral edge 15a.

[0089] Preferably, the elastic element 22 extends from the outer peripheral edge 24 to the inner peripheral edge 15a.

[0090] The extending direction of the elastic element 22 towards the outer peripheral edge 23 is inclined with respect to the extending direction of the inner peripheral edge 14a of the first side portion 14.

[0091] The extending direction of the elastic element 22 towards the outer peripheral edge 24 is inclined with respect to the extending direction of the inner peripheral edge 15a of the second side portion 15.

[0092] The elastic element 22 of the first side portion 14 and the elastic element 22 of the second side portion 15 are disposed relative to each other such that their extending directions converge.

[0093] These characteristics allow the roof 8 to be transformed from a closed or folded configuration to an open configuration, because the open configuration generally requires the roof to be elongated to a certain extent which cannot usually be achieved by a fabric including warp and weft yarns made of carbon fiber.

[0094] Figure 12 Cross-sectional schematic view showing details of the decorative cover 100 for a rigid or semi-rigid element.

[0095] The cover 100 includes a fabric layer 1 applied on a rubber layer 9, preferably butyl rubber.

[0096] The thickness of the rubber layer 9 is less than or equal to 0.5 mm.

[0097] The fabric layer 1 and the rubber layer 9 have corresponding through holes.

[0098] Figure 13 Particularly shown is a seat 200 for a motor vehicle, especially an automobile, which at least partially includes the cover 100.

[0099] As Figures 14 to 17 shown, the seat 200 includes portions of the cover 100 stitched together.

[0100] Referring to Figure 14 , the seat 200 includes a first inner peripheral edge 114a of a first portion 114 of the cover 100 and a second inner peripheral edge 113a of a second portion 113 of the cover 100, and are joined together in such a way as to form a peak portion 116 extending along the lengths of the inner peripheral edges 113a, 114a.

[0101] Reference Figure 15 , the first seam 119 joins the surface of the inner periphery 114a to the surface of the second inner periphery 113a.

[0102] Fold the peak portion 116 provided with the first seam 119 onto a portion of the first part 113 or a portion of the second part 114.

[0103] Place the adhesive material layer 120 at least on the peak portion 116 to hide it.

[0104] Refer to Figure 16 , at least the second seam 121 joins a portion of the adhesive material layer 120 to the first part 113.

[0105] The second seam 121 joins the corresponding portion of the adhesive material layer 20 to the second part 114.

[0106] Refer to Figure 17 , the flap 117 of the inner periphery 114a of the first part 114 is preferably sewn to the flap 118 of the first inner periphery 113a of the second part 113, so that the first part 113 and the second part 114 at least overlap at the corresponding flaps 117, 118.

Claims

1. A motor vehicle ceiling, comprising at least one rubber layer (9), and an outer layer (11) intended to face towards the outside of the motor vehicle and applied to said rubber layer, wherein, The outer layer (11) comprises a fabric (1), wherein the fabric (1) comprises carbon fiber yarns (3) and polymer fiber yarns (4), and the carbon fiber yarns (3) and the polymer fiber yarns (4) are woven to form an interwoven fabric (2), characterized in that, - the interwoven fabric (2) is a twill 2 / 1 interwoven fabric, - the number of filaments of the carbon fiber yarns (3) is 3K, - a protective layer (7) is applied to the interwoven fabric (2), and the protective layer (7) comprises a polymer-based solvent; and wherein, - a tensile test is carried out according to DIN EN 13934-1, and the fabric (1) under traction is stretched by at most 5% and at least 2%; - according to the Bally test, the bending strength of the fabric (1) can exceed 25,000 working cycles; - the protective layer (7) has a water impermeability of 2000 mm water column under a pressure of 2 bar; wherein the roof (8) comprises a body portion (13) designed to define at least the top or roof of the motor vehicle and at least a first side portion (14) and a second side portion (15), the first side portion (14) and the second side portion (15) respectively define at least part of the respective flanks of the motor vehicle, and each of the first side portion (14) and the second side portion (15) comprises a respective elastic element (22); the elastic element (22) is arranged between the outer peripheral edge (23) and the inner peripheral edge (14a) of the first side portion (14); the elastic element (22) is arranged between the outer peripheral edge (24) and the inner peripheral edge (15a) of the second side portion (15).

2. The ceiling according to claim 1, characterized in that, The interwoven fabric (2) comprises weft threads of carbon fiber yarns (3) and warp threads of polymer fiber yarns (4).

3. The ceiling according to claim 1, characterized in that, The interwoven fabric (2) comprises weft threads of polymer fiber yarns (4) and warp threads of carbon fiber yarns (3).

4. The ceiling according to any one of claims 1 to 3, characterized in that, The polymer fiber yarns (4) comprise polyester yarns.

5. The ceiling according to any one of claims 1 to 3, characterized in that, The polymer fiber yarns (4) comprise polypropylene yarns.

6. The ceiling according to any one of claims 1 to 3, characterized in that, The polymer fiber yarns (4) comprise aramid fiber yarns.

7. The ceiling according to any one of claims 1 to 3, characterized in that, The interwoven fabric (2) comprises a pair of polymer fiber weft threads (4) and a single carbon fiber warp thread (3).

8. The ceiling according to claim 1, wherein, The rubber layer (9) is butyl rubber.

9. The ceiling according to claim 1, characterized in that, The roof comprises an inner layer (10), and the inner layer (10) is designed to face the interior of the motor vehicle and is applied to the side of the rubber layer opposite to the outer layer.

10. The ceiling according to claim 9, characterized in that, The inner layer (10) is made of a synthetic material.

11. The ceiling according to claim 10, characterized in that, The synthetic material is an acrylic-based material.

12. The ceiling according to any one of claims 1 to 3 and 8 to 11, characterized in that, At least the body portion (13) comprises the fabric (1).

13. The ceiling according to claim 12, wherein, The inner peripheral edge (14a) of the first side portion (14) and the inner peripheral edge (15a) of the second side portion (15) are connected to the respective first inner peripheral edge (13a) and second inner peripheral edge (13b) of the body portion (13) to define a peak portion extending along the length of the inner peripheral edge.

14. The ceiling according to claim 13, characterized in that, A first seam (19) joins the face of the inner peripheral edge (14a) of the first side portion (14) to the face of the first inner peripheral edge (13a) of the body portion (13).

15. The ceiling according to claim 13, characterized in that, The first seam (19) joins the inner peripheral edge (15a) of the second side portion (15) to the second inner peripheral edge (13b) of the main body portion (13).

16. The ceiling according to claim 13, characterized in that, The peak portion (16) provided with the first seam (19) is folded onto a part of the main body portion (13) or a part between the first side portion (14) and the second side portion (15).

17. The ceiling according to claim 13, characterized in that, The adhesive material layer (20) is placed at least on the peak portion (16) to hide it.

18. The ceiling according to claim 17, characterized in that, The ceiling includes at least a second seam (21) that joins a part of the adhesive material layer (20) to the main body portion (13).

19. The ceiling according to claim 18, characterized in that, The second seam (21) joins the corresponding part of the adhesive material layer (20) to the first side portion (14).

20. The ceiling according to claim 18, characterized in that, The second seam (21) joins the corresponding part of the adhesive material layer (20) to the second side portion (15).

21. The ceiling according to claim 13, characterized in that, The flap (17) of the inner peripheral edge (14a) of the first side portion (14) is sewn to the flap (18) of the first inner peripheral edge (13a) of the main body portion (13), so that the main body portion (13) and the first side portion (14) overlap at least at the corresponding flaps (17, 18).

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