Nonwoven porous three-dimensional matrix structures for vehicular applications

Abstract

The present disclosure teaches the formation of non-woven porous three-dimensional (3D) matrix structures that are particularly suited for use in vehicle applications, such as vehicle foam seats, to replace a portion of the foam while maintaining cushioning and defining relatively effective airflow channels for heating and cooling.

Description

[0001] Cross-reference to earlier applications

[0002] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 367,184, filed on June 28, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to the formation of nonwoven porous three-dimensional (3D) matrix structures that are particularly suitable for use in vehicle applications such as vehicle foam seats to replace a portion of the foam while maintaining cushioning and defining relatively efficient airflow channels for heating and cooling.

[0004] background

[0005] Knitted and / or reticulated foams have been reported for use as spacer fabrics, for vehicle seat trim covers, and for use throughout foam pads / around foam pads. Spacer fabrics refer to the feature of such materials that allow air circulation through seats, especially seats that have active cooling or heating functions under compression. The goal of the material is therefore to allow air to pass through its structure and provide relatively more efficient cooling and heating. Static air spaces may be required to provide insulation.

[0006] Nonetheless, there remains a need for three-dimensional (3D) materials that are relatively easy to form into desired shapes and that have the ability to compress and recover as well as relatively enhanced air flow properties that provide relatively more efficient vehicle seat cooling and heating performance.

[0007] Summary of the Invention

[0008] A ventilated vehicle seat comprising a polymer foam wherein a portion of the foam is replaced with a three-dimensional nonwoven self-supporting matrix structure wherein the three-dimensional nonwoven self-supporting matrix structure: (a) has a thickness in the range of 2.0 mm to 30.0 mm; (b) has a strength of 100 lbs / ft 2 and (c) an ASTM D 737 air flow rate of greater than or equal to 800 cubic feet per minute at 125 Pa.

[0009] A method for forming a ventilated vehicle seat, the method comprising: providing a polymer foam formed for use in a vehicle seat; and replacing a portion of the foam with a three-dimensional nonwoven self-supporting matrix structure, wherein the three-dimensional nonwoven self-supporting matrix structure: (a) has a thickness in the range of 2.0 mm to 30.0 mm; (b) has a pressure of 100 lbs / ft 2 and (c) an ASTM D737 air flow rate of greater than or equal to 800 cubic feet per minute at 125 Pa.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a cross-sectional view of a portion of a vehicle seat in which portions of the foam are replaced by inserts of a porous 3D self-supporting nonwoven matrix structure.

[0012] Figure 2A is another cross-sectional view of a portion of a vehicle seat in which a porous 3D self-supporting nonwoven matrix structure replaces a portion of the vehicle foam in the lower portion of the vehicle seat.

[0013] Figure 2B is another cross-sectional view of a portion of a vehicle seat with a porous 3D self-supporting nonwoven matrix structure replacing a portion of the vehicle foam in the lower portion of the vehicle seat illustrating the weight of a passenger in contact with the vehicle seat.

[0014] Figure 3A is another cross-sectional view of a portion of a vehicle seat with a porous 3D self-supporting nonwoven matrix structure replacing a portion of the vehicle foam in the lower portion of the vehicle seat, illustrating a preferred location for an HVAC system fan.

[0015] Figure 3B is another cross-sectional view of a portion of a vehicle seat in which a porous 3D self-supporting nonwoven matrix structure replaces a portion of the vehicle foam in the lower portion of the vehicle seat, illustrating how the weight of a typical passenger does not interfere with the operation of the HVAC system fan.

[0016] Figure 4 Another cross-sectional view of a vehicle seat is provided, illustrating how the porous 3D self-supporting nonwoven matrix structure provides air flow channels in the foam.

[0017] Detailed Description

[0018] The present invention relates to a nonwoven porous three-dimensional (3D) matrix structure that is used to connect to and / or replace a portion of a foam material used in a ventilated vehicle seat. The nonwoven porous 3D matrix structure is preferably a self-supporting structure, which means that the 3D matrix structure can support itself under its own weight and thus can be used to strengthen the foam, maintain the necessary cushioning and define the characteristics of the air channel when replacing a portion of the foam material.

[0019] The nonwoven porous self-supporting 3D matrix structure herein is preferably selected from a nonwoven consisting of filaments fused at their intersections. Preferably, the filaments are thermoplastic filaments derived from polyethylene, polypropylene, metallocene polymerized polyolefins, polyamides or polyurethanes. Particularly preferred filaments are derived from polyamides. Other preferred materials for use as the self-supporting 3D matrix herein include, for example, those available from Colbond (Enka, NC). Nylon pad. In addition, the nonwoven porous self-supporting 3D matrix structure herein can adopt the three-dimensional structure pad described in WO2018 / 206568, the teachings of which are incorporated herein by reference.

[0020] Therefore, the long filaments of the porous self-supporting 3D matrix structure preferably comprise extruded polymer filaments. Accordingly, the porous self-supporting 3D structure is provided by extruding polymer filaments and collecting the extruded filaments into a 3D structure by allowing the filaments in a molten state to bend, entangle and contact each other. The bending and entanglement of the extruded filaments can be started by collecting the filaments onto a profiled surface, which can then define the self-supporting 3D structure herein.

[0021] The self-supporting 3D structures herein may be shaped into any desired 3D form, such as a series of hills and valleys spaced apart at specified distances or adjacent to each other and placed in parallel lines or in a staggered pattern.

[0022] The extruded, entangled filaments within the porous self-supporting 3D structure herein may have an average diameter in the range of 100 μm-2000 μm, more preferably 200 μm-1500 μm, even more preferably 300 μm-1100 μm, and most preferably 500 μm-900 μm. As described above, the filaments of the porous self-supporting 3D matrix structure herein are thermally bonded at their intersections. Preferably, the filaments have a density of 100 g / m 2 -1500g / m 2 , more preferably 300g / m 2 -800g / m 2 , or even more preferably 300 g / m 2 -400g / m 2 The filaments also preferably have an open area of ​​at least 75% by volume, preferably at least 90% by volume, more preferably at least 95% by volume.

[0023] Preferably, the porous self-supporting 3D nonwoven matrix herein has the thickness in the range of 2.0mm-30.0mm (comprising all single values ​​and increments therein).For example, in a particularly preferred embodiment, the porous self-supporting 3D nonwoven matrix herein has the thickness of 10.0 millimeters, 11.0 millimeters, 12.0 millimeters, 13.0 millimeters, 14.0 millimeters, 15.0 millimeters, 16.0 millimeters, 17.0 millimeters, 18.0 millimeters, 19.0 millimeters or 20.0 millimeters.In addition, the porous self-supporting 3D nonwoven matrix herein preferably has quite consistent thickness, and this refers to the feature that thickness variation is no more than + / -1.0 millimeters or + / -0.5 millimeters or + / -0.1 millimeter.Example further, the self-supporting 3D nonwoven matrix herein can preferably have the thickness of 15.0 millimeters, and its thickness variation is no more than + / -1.0 millimeters or + / -0.5 millimeter or + / -0.1 millimeter.

[0024] The porous 3D self-supporting nonwoven matrix herein preferably has a strength of 5 ounces per square yard (160.5 g / m2) at the above thickness of 2.0 mm to 30.0 mm. 2 ) to 30.0 ounces per square yard (1017.2 g / m 2 ) range (including all individual values ​​and increments therein). At least 90% of the self-supporting nonwoven matrix is ​​open, and the pad shows at least 70% or greater, more preferably in the range of 70% to 90% (including all individual values ​​and increments therein) resilience according to ASTM D6524 measurement. The 3D porous self-supporting nonwoven matrix herein is also preferably displayed in the longitudinal direction (production direction of the 3D nonwoven matrix) maximum load tensile strength in the range of 20 to 60 pounds of force, a Young's modulus value in the range of 0.05 to 0.11 kilograms per square inch, and a maximum percent elongation in the range of 50% to 110%, using ASTM D6818 method at 12 inches per minute, 3 inches of gauge length and 4 inches of wide samples Test. The 3D porous self-supporting nonwoven matrix herein also preferably exhibits a maximum load tensile strength in the transverse direction (vertical direction when producing the 3D nonwoven matrix) in the range of 40 to 120 pounds, a Young's modulus value in the range of 0.2 to 0.8 kilograms per square inch, and an elongation in the range of 10% to 50%, tested using the ASTM D6818 method at 12 inches per minute, a gauge length of 3 inches, and a 4-inch wide sample.

[0025] The porous 3D self-supporting nonwoven substrate herein is also preferably those providing a deflection indentation force deflection of 42 pounds to 55 pounds, measured at 25% deflection on a 4.0 inch sample according to ASTM D357B. In addition, the porous 3D self-supporting nonwoven substrate herein is preferably those showing a thickness retention of 50.0% to 100% at 100 pounds per square foot or a thickness retention of 25.0% to 95.0% at 200 pounds per square foot.

[0026] It is contemplated that the porous 3D self-supporting nonwoven matrix herein is particularly suitable for air-cooled / heated vehicle seats. Figure 1 As shown in the figure, the foam portion is indicated by 12, and the insert of the porous 3D self-supporting nonwoven matrix structure is shown as item 14. As can be seen, the insert 14 of the porous 3D self-supporting nonwoven matrix structure replaces a portion of the foam, and preferably contains 5.0 wt% or less of embedded foam in the 3D structure, even more preferably 3.0 wt% or less of embedded foam, even more preferably 2.0 wt% or less of embedded foam, and finally the 3D structure preferably does not contain any embedded foam.

[0027] The vehicle HVAC system fan 16 can then drive cold / warm air through the porous self-supporting 3D nonwoven matrix 14 with a preferred air flow greater than or equal to 800 cubic feet per minute (cfm), measured at 125Pa by ASTM D737. More preferably, the air flow is in the range of 800cfm to 1360cfm. Also as shown in the figure, preferably a spacer layer 18 of porous 3D self-supporting nonwoven can be included below the cover layer 20. The spacer layer itself can have a preferred thickness in the range of 3.0 millimeters to 20.0 millimeters, and is provided in a similar air flow in the range of 800cfm to 1360cfm. Therefore, when implementing the vehicle HVAC system 16, the HVAC system fan 16 can now drive cold / warm air through the porous 3D self-supporting nonwoven matrix 14 and the spacer layer 18 and then by the cover layer 20 that the vehicle passenger may be provided with.

[0028] Figure 2A and 2B A view of a portion of the vehicle seat of the present invention is shown again in cross section, wherein a porous 3D self-supporting nonwoven matrix 14 is inserted into and replaces a portion of the vehicle foam 12 in the lower portion of the vehicle seat. As can now be understood, the porous 3D self-supporting nonwoven matrix 14 can also act as a duct, channel or tunnel for the cool / warm air flow driven by the vehicle HVAC system fan 16.

[0029] Figure 2B The cross-section diagram illustrates Figure 2A 1, wherein a passenger has engaged with the vehicle seat and placed his weight on the vehicle seat. For clarity, the cover layer 20 and the spacer layer 18 have been removed. As can be seen, although a portion of the foam 12 may compress, the porous 3D self-supporting nonwoven matrix 14 preferably does not compress, or the porous 3D self-supporting nonwoven matrix 14 shows the thickness retention rate indicated herein, and the ability of the porous 3D nonwoven matrix 14 is retained so that it can continue to provide a path for the flow of cold / warm air in the form of a duct, channel or tunnel.

[0030] It should be understood that without the porous 3D nonwoven matrix 14, the weight of the passenger will cause the foam to compress, and the deformed foam will then reduce any cut-out space in the foam for air flow. The ability of the porous 3D nonwoven matrix to provide limited compression at typical passenger weights (50 pounds to 300 pounds) thus provides a more efficient vehicle seat configuration at a relatively light overall weight while maintaining the efficiency of the HVAC system when operating in the vehicle. In this context, for a given thickness, the porous 3D nonwoven matrix herein is 100 lbs / ft 2 Shows 50-100% thickness retention under pressure or at 200lbs\ft 2 Those that show 25% to 95% thickness retention under pressure.

[0031] Table 1 below shows the thickness retention of the porous 3D nonwoven self-supporting matrix material under pressure in this article:

[0032] Table 1 Thickness retention rate

[0033]

[0034] In the above table, FB means flat back, i.e. the back of the material is intentionally flat without peaks. The mark 75 / 25 means that 75% by weight of the material is in the body and 25% is on the surface (flat back). The mark 60 / 40 means that 60% by weight of the material is in the body and 40% is on the surface (flat back). As can be seen from the above thickness retention evaluation, the porous 3D self-supporting nonwoven matrix structure herein is more preferably at 100 lbs / ft 2 Maintain more than 80.0% of its thickness at 200lbs / ft 2 The thickness thereof is maintained at 65.0% or more.

[0035] Figure 3A and 3B and Figure 2A and 2BSimilarly, and with the additional feature of the preferred location of the HVAC system fan 16 within the cutout area of ​​the porous 3D nonwoven matrix 14. As can be seen from Figures 3C and 3D, when a vehicle occupant engages with the vehicle seat, the 3D porous nonwoven matrix again preferably does not fully compress and deform under the weight of a typical occupant (50 pounds to 300 pounds), and the HVAC system fan 16 is not damaged by the presence of some compressed foam interfering with its operation.

[0036] Figure 4 Another view is provided on how to use the porous 3D nonwoven matrix 14 in a vehicle seat to more effectively provide a path for the flow of cool / warm air in the form of ducts, channels or tunnels in the foam 12. As now in Figure 4 As shown in FIG, such a path can be located in a vehicle seat back 18 and a seat cushion 20, wherein a portion of the foam body 12 is replaced by a porous 3D nonwoven matrix 14. Therefore, it can be understood that one or more air flow paths can now be provided within the foam body 12 by using the porous 3D nonwoven matrix 14 herein to provide circulation of warm / cold air while reducing weight, and wherein such a path is not affected due to compression resistance when a passenger engages with the vehicle seat. As described above, the flow rate of air delivered at the seat back 20 or the surface 22 of the seat cushion is preferably maintained and falls within a preferred range of 800 cfm to 1360 cfm.

[0037] Expanding on the above, it is more particularly contemplated that the porous 3D nonwoven matrix 14 herein, when used in a vehicle foam seat, can provide the aforementioned airflow path while also providing mechanical performance characteristics similar to the foam 12 employed, while also providing the aforementioned compression resistance. Specifically, preferred foams that can be replaced with a portion of the 3D nonwoven matrix 14 herein include polyurethane foams having the following properties: (1) 24-48 kg / m 3 Foam density; (2) 25-70 (lbf / 50 in) of foam deflection indentation force (IFD); at 100 lbs / ft 2 Thickness retention in the range of 85% to 93% at 500lbs / ft 2 The thickness retention rate is in the range of 25% to 55%.

[0038] With regard to replacing a portion of the polyurethane foam, it is contemplated herein that up to 50% by weight of the preferred polyurethane foam used in the cushions and chair backs may be replaced by the 3D nonwoven matrix. Thus, 1% to 50% by weight (including all values ​​and increments therein) of the polyurethane in the seat cushions and / or chair backs may be replaced by the 3D nonwoven matrix herein. For example, 10%-50% of the foam, or 20% to 50% of the foam, or 30% to 50% of the foam, or 40% to 50% of the foam may be replaced by the porous self-supporting 3D nonwoven matrix structure herein.

[0039] It is further contemplated herein that the porous 3D nonwoven matrix 14 herein may include an additional layer of spunbond nonwoven fabric, needle-punched nonwoven fabric, or knitted fabric (e.g., circular knitted fabric) on one side of the porous 3D nonwoven matrix in contact with the cover layer 20. Such a spunbond nonwoven or woven fabric layer may preferably have a thickness of up to 1.0 mm and a basis weight in the range of 20 gsm to 200 gsm. Such a spunbond nonwoven fabric, needle-punched nonwoven fabric, or knitted fabric may preferably be made of those polymer resins used to make the 3D nonwoven matrix itself. That is, thermoplastic filaments derived from polyethylene, polypropylene, metallocene polymerized polyolefins, polyamides, or polyurethanes.

[0040] The porous 3D nonwoven matrix 14 herein may preferably contain a flame retardant. Such flame retardants preferably include non-halogenated flame retardants, which are preferably present in an amount of up to 10.0% by weight in the nonwoven matrix 14. Other conceivable additives include antimicrobial agents, such as silver, copper or zinc, which are preferably present at a level of 1.0% by weight to 10.0% by weight.

[0041] The porous 3D nonwoven matrix herein also exhibits many other additional advantages when used to replace a portion of a vehicle foam seat. This includes, for example, that the surface of the 3D nonwoven matrix herein enables it to mechanically adhere to the foam, thereby eliminating the need to use an adhesive or clip mechanism to fix the 3D nonwoven matrix in place. In addition, the 3D nonwoven matrix herein can be cut into a desired thickness or shape, which may be necessary to replace a portion of a vehicle foam seat.

[0042] The porous 3D nonwoven matrix herein can also be stacked. As mentioned above, the porous 3D nonwoven matrix herein can have a thickness in the range of 2.0mm to 30.0mm. Therefore, in order to obtain a given thickness selected within this range, multiple such 3D nonwoven matrixes can be stacked to provide a multilayer 3D nonwoven matrix.

Claims

1. A ventilated vehicle seat comprising a polymer foam wherein a portion of the foam is replaced by a three-dimensional nonwoven self-supporting matrix structure wherein the three-dimensional nonwoven self-supporting matrix structure: (a) has a thickness in the range of 2.0 mm to 30.0 mm; (b) has a pressure drop of 100 lbs / ft 2 and (c) an ASTM D 737 air flow rate of greater than or equal to 800 cubic feet per minute at 125 Pa.

2. The ventilated vehicle seat of claim 1 wherein up to 50% of the foam is replaced by the three-dimensional nonwoven self-supporting matrix structure.

3. The ventilated vehicle seat of claim 1, wherein the ASTM D 737 air flow rate at 125 Pa is 800 cfm to 1360 cfm.

4. The ventilated vehicle seat of claim 1, wherein the three-dimensional nonwoven self-supporting matrix structure has a thickness of 160.5 g / m 2 Up to 1017.2g / m 2 Unit weight.

5. The ventilated vehicle seat of claim 1, wherein the three-dimensional nonwoven self-supporting matrix structure exhibits an ASTM D 6524 resilience of at least 70% or greater.

6. The ventilated vehicle seat of claim 1 wherein the three-dimensional nonwoven self-supporting matrix structure is 100 lbs / ft 2 When the thickness is maintained at 80% or more, it shows a thickness maintenance rate.

7. The ventilated vehicle seat of claim 1 wherein the three-dimensional nonwoven self-supporting matrix structure comprises thermoplastic filaments.

8. The ventilated vehicle seat of claim 2, wherein the thermoplastic filaments are selected from polyethylene, polypropylene, metallocene polymerized polyolefins, polyamides, or polyurethanes.

9. The ventilated vehicle seat of claim 2, wherein the thermoplastic filaments have a diameter in the range of 100 μm to 2000 μm.

10. The ventilated vehicle seat of claim 1, wherein the foam comprises a foam having a density of 24 kg / m 3 Up to 48kg / m 3 Polyurethane foam.

11. The ventilated vehicle seat of claim 1 wherein the three-dimensional nonwoven self-supporting matrix structure comprises a layer of spunbond, needlepunch or knitted fabric having a thickness of up to 1.0 mm and a basis weight in the range of 20 gsm to 300 gsm.

12. The ventilated vehicle seat of claim 1 wherein the three-dimensional nonwoven self-supporting matrix structure contains a non-halogenated flame retardant.

13. The ventilated vehicle seat of claim 1 wherein the three-dimensional nonwoven self-supporting matrix structure contains an antimicrobial agent.

14. The ventilated vehicle seat of claim 1 wherein said three-dimensional nonwoven self-supporting matrix structure contains 5.0% or less of foam embedded within said three-dimensional structure.

15. A method of forming a ventilated vehicle seat, the method comprising: a. Providing a polymer foam formed for a vehicle seat; b. replacing a portion of the foam with a three-dimensional nonwoven self-supporting matrix structure, wherein the three-dimensional nonwoven self-supporting matrix structure: (a) has a thickness in the range of 2.0 mm to 30.0 mm; (b) at 100 lbs / ft 2 and (c) an ASTM D 737 air flow rate of greater than or equal to 800 cubic feet per minute at 125 Pa.

16. The method of claim 15, wherein up to 50% of the foam is replaced by the three-dimensional nonwoven self-supporting matrix structure.

17. The method of claim 15, wherein the ASTM D 737 air flow rate at 125 Pa is 800 cfm to 1360 cfm.

18. The method of claim 15, wherein the three-dimensional nonwoven self-supporting matrix structure has a thickness of 160.5 g / m 2 Up to 1017.2g / m 2 Unit weight.

19. The method of claim 15, wherein the three-dimensional nonwoven self-supporting matrix structure exhibits an ASTM D 6524 resilience of at least 70% or greater.

20. The method of claim 15, wherein the three-dimensional nonwoven self-supporting matrix structure is at 100 lbs / ft 2 When the thickness is maintained at 80% or more, it shows a thickness maintenance rate.

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