Nonwoven Porous Three-Dimensional Matrix Structure for Vehicle Use

Abstract

Forming a nonwoven porous three-dimensional (3D) matrix structure that is particularly suitable for vehicle applications, such as in vehicle foam seats, to replace a portion of the foam while maintaining cushioning and defining a relatively efficient air flow path for heating and cooling.

Description

Technical Field

[0001] Cross - Reference to Related Applications

[0001] This application claims the priority and benefit of U.S. Provisional Patent Application No. 63 / 367,184, filed on June 28, 2022, the entire disclosure of which is incorporated herein by reference.

[0002]

[0002] The present invention is directed to the formation of a non - woven porous three - dimensional (3D) matrix structure, particularly suitable for vehicle applications, such as in vehicle foam seats, that maintains cushioning and defines a relatively efficient air flow path for heating and cooling, while replacing a portion of the foam.

Background Art

[0003]

[0003] Knitted fabric and / or reticulated foam have been reported to be used as spacer fabrics within the trim cover of vehicle seats and through / peripherally around the foam cushion. A spacer fabric is a reference to the characteristic that such materials enable air flow within the seat configured to provide active heating or cooling, particularly during compression. Therefore, these materials are intended to allow air to pass through their structures and provide relatively more efficient heating and cooling. A still air space may be desirable to provide insulation.

[0004]

[0004] Nevertheless, there remains a need for a three - dimensional (3D) material that can be formed into a desired shape relatively easily and has an improved ability to compress and recover, along with relatively enhanced air flow performance that provides relatively more efficient heating and cooling performance for vehicle seats.

Summary of the Invention

[0005]

[0005] A vehicle ventilation seat including a polymer foam, wherein a part of the foam is replaced with a three-dimensional nonwoven self-supporting matrix structure, and the three-dimensional nonwoven self-supporting matrix structure has (a) a thickness in the range of 2.0 mm to 30.0 mm, (b) a thickness retention of 50.0% to 100% at 100 lbs / ft 2 and (c) an ASTM D 737 air flow of 800 cubic feet per minute or more at 125 Pa.

[0006]

[0006] A method of forming a vehicle ventilation seat, comprising providing a polymer foam configured for a vehicle seat and replacing a part of the foam with a three-dimensional nonwoven self-supporting matrix structure, and the three-dimensional nonwoven self-supporting matrix structure has (a) a thickness in the range of 2.0 mm to 30.0 mm, (b) a thickness retention of 50.0% to 100% at 100 lbs / ft 2 and (c) an ASTM D 737 air flow of 800 cubic feet per minute or more at 125 Pa.

Brief Description of the Drawings

[0007] Brief Description of the Drawings

Figure 1

[0007] A cross-sectional view of a part of a vehicle seat in which the foam part is replaced with an insert of a porous three-dimensional self-supporting nonwoven matrix structure.

Figure 2A

[0008] Another cross-sectional view of a part of a vehicle seat in which the porous three-dimensional self-supporting nonwoven matrix structure replaces a part of the vehicle foam in the lower part of the vehicle seat.

Figure 2B

[0009] Another cross-sectional view of a part of a vehicle seat in which the porous three-dimensional self-supporting nonwoven matrix structure replaces a part of the vehicle foam in the lower part of the vehicle seat, and in this figure, the weight of a passenger sitting on the vehicle seat is shown.

Figure 3A

[0010] Another cross-sectional view of a portion of a vehicle seat where a porous three-dimensional self-supporting nonwoven matrix structure replaces a portion of the vehicle foam in the lower part of the vehicle seat, and this figure illustrates a preferred position of the fan of the HVAC system.

Figure 3B

[0011] Another cross-sectional view of a portion of a vehicle seat where a porous three-dimensional self-supporting nonwoven matrix structure replaces a portion of the vehicle foam in the lower part of the vehicle seat, and this figure illustrates how the weight of a typical occupant does not interfere with the operation of the fan of the HVAC system.

Figure 4

[0012] Present a cross-sectional view of a vehicle seat that illustrates how the porous three-dimensional self-supporting nonwoven matrix structure provides an air flow path within the foam.

Mode for Carrying Out the Invention

[0008] Detailed Description

[0013] The present invention is directed to a nonwoven porous three-dimensional (3D) matrix structure that is attached to and / or used to replace a portion of the foam material utilized in a vehicle ventilation seat. The nonwoven porous three-dimensional matrix structure is preferably self-supporting, which is a reference to the feature that the three-dimensional matrix structure can support itself under its own weight and, therefore, can reinforce the foam, maintain the necessary cushioning properties, and define an air passage when replacing a portion of the foam material.

[0009]

[0014] The nonwoven porous self - standing three - dimensional matrix structure herein is preferably selected from nonwoven fabrics composed of filaments fused at intersections. Preferably, the filaments are thermoplastic filaments made from polyethylene, polypropylene, metallocene - polymerized polyolefin, polyamide, or polyurethane. Particularly preferred filaments are made from polyamide. Other materials preferred for use as the self - standing three - dimensional matrix herein include, for example, Enkamat® nylon mats available from Colbond (Enka, N.C.). In addition, the nonwoven porous self - standing three - dimensional matrix structure herein can use the three - dimensionally structured mats described in International Publication No. WO 2018 / 206568, the teachings of which are incorporated by reference.

[0010]

[0015] Therefore, the filaments of the porous self - standing three - dimensional matrix structure preferably include extruded polymer filaments. Thus, the porous self - standing three - dimensional structure is provided by extruding polymer filaments and gathering the extruded filaments into a three - dimensional structure by allowing the filaments to bend, intertwine, and contact each other in a molten state. The bending and intertwining of the extruded filaments may be initiated by gathering the filaments on a contour - forming surface, thereby defining the self - standing three - dimensional structure herein.

[0011]

[0016] The self - standing three - dimensional structure herein can be shaped into any desired three - dimensional shape, such as a series of hills and valleys arranged at a predetermined distance apart or adjacent to each other, arranged in parallel lines or in an alternating configuration.

[0012]

[0017] The diameter of the extruded intertwined filaments within the porous self-supporting three-dimensional structure in this specification can have an average diameter in the range of 100 μm to 2000 μm, more preferably in the range of 200 μm to 1500 μm, even more preferably in the range of 300 μm to 1100 μm, and most preferably in the range of 500 μm to 900 μm. As described, the filaments of the porous self-supporting three-dimensional matrix structure in this specification are thermally bonded at these intersections. Preferably, the filaments are 100 g / m 2 ~1500 g / m 2 、more preferably 300 g / m 2 ~800 g / m 2 、or even more preferably 300 g / m 2 ~400 g / m 2 and have a weight per thickness in the range. 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.

[0013]

[0018] Preferably, the porous self-supporting three-dimensional non-woven matrix in this specification has a thickness in the range of 2.0 mm to 30.0 mm, including all individual values and increments within that range. For example, in a particularly preferred embodiment, the porous self-supporting three-dimensional non-woven matrix in this specification has a thickness of 10.0 mm, 11.0 mm, 12.0 mm, 13.0 mm, 14.0 mm, 15.0 mm, 16.0 mm, 17.0 mm, 18.0 mm, 19.0 mm, or 20.0 mm. In addition, the porous self-supporting three-dimensional non-woven matrix in this specification preferably has a relatively uniform thickness, which refers to the feature that the thickness does not vary by more than ±1.0 mm, or ±0.5 mm, or ±0.1 mm. As a further example, the self-supporting three-dimensional non-woven matrix in this specification preferably has a thickness of 15.0 mm and the thickness does not vary by more than ±1.0 mm, or ±0.5 mm, or ±0.1 mm.

[0014]

[0019] The porous three-dimensional self-supporting non-woven matrix in this specification preferably has the above thickness of 2.0 mm to 30.0 mm and 5 ounces per square yard (160.5 g / m2 ) to 30.0 ounces per square yard (1017.2 g / m 2 ) and includes all individual values and increments within that range, having a weight. At least 90% of the self - standing non - woven matrix is open, and the mat exhibits elasticity under ASTM D6524, including all individual values and increments within the range of at least 70% or more, more preferably in the range of 70% - 90%. The three - dimensional porous self - standing non - woven matrix herein also preferably has a maximum load tensile strength in the range of 20 - 60 pounds, a Young's modulus value in the range of 0.05 - 0.11 kilograms per square inch, and a maximum elongation rate of 50 - 110% in the machine direction (the direction of the three - dimensional non - woven matrix during manufacture), as determined using the method of ASTM D6818 tested on a sample with a rate of 12 inches per minute, a gauge length of 3 inches, and a width of 4 inches. The three - dimensional porous self - standing non - woven matrix herein also preferably has a maximum load tensile strength in the range of 40 - 120 pounds, a Young's modulus value in the range of 0.2 - 0.8 kilograms per square inch, and an elongation in the range of 10 - 50% in the cross - direction (the orthogonal direction across the three - dimensional non - woven matrix during manufacture), as determined using the method of ASTM D6818 tested on a sample with a rate of 12 inches per minute, a gauge length of 3 inches, and a width of 4 inches.

[0015]

[0020] The porous three - dimensional self - standing non - woven matrix herein also preferably provides an indentation force deflection at 25% deflection of 42 lbs - 55 lbs in accordance with ASTM D357B on a 4.0 - inch sample. Additionally, the porous three - dimensional self - standing non - woven matrix herein preferably exhibits a thickness retention rate of 50.0% - 100% at 100 lbs per square foot or 25.0% - 95.0% at 200 lbs per square foot.

[0016]

[0021] The porous three-dimensional self-standing nonwoven matrix described herein is considered particularly suitable for vehicle seats that are cooled / heated. As shown in FIG. 1, which is a cross-sectional view of a portion of vehicle seat 10, the foam portion is identified as 12, and the insert of the porous three-dimensional self-standing nonwoven matrix structure is seen as article 14. As can be seen, the insert 14 of the porous three-dimensional self-standing nonwoven matrix structure replaces a portion of the foam and preferably contains 5.0% by weight or less of the embedded foam within the three-dimensional structure, even more preferably 3.0% by weight or less of the embedded foam, and even more preferably 2.0% by weight or less of the embedded foam. Finally, the three-dimensional structure preferably does not contain the embedded foam.

[0017]

[0022] And the fan 16 of the vehicle HVAC system can drive cold / heat air through the porous self-standing three-dimensional nonwoven matrix 14 at a preferred air flow rate of 800 cubic feet per minute (cfm) or more, measured by ASTM D737 at 125 Pa. More preferably, the air flow is in the range of 800 cfm to 1360 cfm. Also as shown, preferably, the spacer layer 18 of the porous three-dimensional self-standing three-dimensional nonwoven can be included under the cover material layer 20. The spacer layer itself has a preferred thickness in the range of 3.0 mm to 20.0 mm and can provide a similar air flow rate in the range of 800 cfm to 1360 cfm. Thus, here, the fan 16 of the HVAC system can drive cold / heat air through the porous three-dimensional self-standing nonwoven matrix 14 and then through the cover material layer 20, so that it can be set by the vehicle occupant when the vehicle HVAC system 16 is operating.

[0018]

[0023] Figures 2A and 2B again illustrate in cross-section a portion of a vehicle seat the features herein of a porous three-dimensional self-supporting nonwoven matrix 14 being inserted into the lower portion of a vehicle seat to replace a portion of a vehicle foam 12 in the lower portion of the vehicle seat. As can be understood herein, the porous three-dimensional self-supporting nonwoven matrix 14 can otherwise function as a duct, channel or tunnel for the flow of cold / hot air driven by a fan 16 of a vehicle HVAC system.

[0019]

[0024] Figure 2B illustrates in cross-section the vehicle seat of Figure 2A with an occupant sitting on the vehicle seat and placing weight on the vehicle seat. The cover material 20 and the spacer layer 18 have been removed for clarity. As can be observed, a portion of the foam 12 can be compressed, but the porous three-dimensional self-supporting nonwoven matrix 14 preferably does not compress or exhibits the thickness retention rate described herein, and the ability of the porous three-dimensional nonwoven matrix 14 is maintained such that the porous three-dimensional nonwoven matrix 14 can continue to provide a path in the form of a duct, channel or tunnel for the flow of cold / hot air.

[0020]

[0025] It should be recognized that in the absence of the porous three-dimensional nonwoven matrix 14, the foam is otherwise compressed by the weight of the occupant, and any cut-out spaces in the foam for the flow of air are reduced by the deformed foam. Thus, the ability of the porous three-dimensional nonwoven matrix to provide compression suppressed under the weight of a typical occupant (50 lbs to 300 lbs) provides a vehicle seat configuration of relatively low total weight and greater efficiency that also maintains the efficiency of the HVAC system during operation within the vehicle. In such context, a given thickness of the porous three-dimensional nonwoven matrix herein is a thickness showing a thickness retention rate of 50 - 100% at a pressure of 100 lbs / ft 2 or a thickness retention rate of 25 - 95% at a pressure of 200 lbs / ft 2 .

[0021]

[0026] The following Table 1 shows the thickness retention rate under pressure for the porous three-dimensional nonwoven self-supporting matrix material in this specification.

[0022]

[0027]

Table 1

[0023]

[0028] In the above table, FB indicates a flat back, which means that the back of the material is intentionally flat without peaks. By the reference to 75 / 25, it is specified that 75% of the weight of the material is in the bulk part and 25% is on the surface (flat back). By the reference to 60 / 40, it is specified that 60% of the weight of the material is in the bulk part and 40% is on the surface (flat back). As can be seen from the above evaluation of the thickness retention rate, the porous three-dimensional nonwoven self-supporting nonwoven matrix structure in this specification preferably retains 80.0% or more of its thickness at 100 lbs / ft 2 and retains 65.0% or more of its thickness at 200 lbs / ft. 2

[0024]

[0029] Figures 3A and 3B are similar to Figures 2A and 2B and show further features of the preferred position of the HVAC system fan 16 within the cutout region of the porous three-dimensional nonwoven matrix 14. As can be seen from Figures 3C and 3D, when a vehicle occupant is sitting on a vehicle seat, the three-dimensional porous nonwoven matrix preferably does not fully compress and deform under the weight of a typical occupant (50 lbs to 300 lbs), and the fan 16 of the HVAC system is not impaired due to the presence of some compressed foam that interferes with its operation.

[0025]

[0030] ​Figure 4 provides another view of how the porous three-dimensional nonwoven matrix 14 can be used within a vehicle seat to more effectively provide a path within the foam 12 in the form of a duct, channel, or tunnel for the flow of cold / hot air. As shown here in Figure 4, such a path can be positioned in both the vehicle seat back 18 and the seat cushion 20 where a portion of the foam 12 has been replaced by the porous three-dimensional nonwoven matrix 14. Thus, it can be recognized here that one or more air flow paths can be provided within the foam 12 by the use of the porous three-dimensional nonwoven matrix 14 herein to provide both weight reduction and cold / hot air circulation, and such paths are not impaired even when an occupant is sitting on the vehicle seat due to their compression resistance. As described above, the flow of air supplied to the seat back 20 or the surface 22 of the seat cushion is maintained and preferably falls within a preferred range of 800 cfm to 1360 cfm.

[0026]

[0031] To explain the above in more detail, the porous three-dimensional nonwoven matrix 14 herein is more particularly considered to be able to provide the above-described path for the air flow while providing the aforementioned compression resistance when used in a vehicle foam seat, and at the same time, can also provide characteristics of mechanical properties similar to those of the foam 12 used. In particular, the preferred foam that can replace the portion of the three-dimensional nonwoven matrix 14 herein includes a polyurethane foam having the following properties, namely, (1) a foam density of 24 to 48 kg / m 3 ; (2) an indentation force deflection (IFD) of 25 to 70 (25 to 70 pounds of force per 50 inches) of the foam; a thickness retention rate in the range of 85% to 93% at 100 lbs / ft 2 ; and a thickness retention rate of 25% to 55% at 500 lbs / ft 2 .

[0027]

[0032] Reference is made to the replacement of a portion of the polyurethane foam, and it is contemplated herein that preferably up to 50% by weight of the preferred polyurethane foam used in cushions and seatbacks can be replaced by a three-dimensional nonwoven matrix. Thus, 1% to 50% by weight of the polyurethane in the seat cushion and / or seatback, including all values and increments within that range, can be replaced by the three-dimensional nonwoven matrix herein. For example, 10% to 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 can be replaced by the porous self-supporting three-dimensional nonwoven matrix structure herein.

[0028]

[0033] It is further contemplated herein that the porous three-dimensional nonwoven matrix 14 can include the addition of a layer of spunbond nonwoven, needle-punched nonwoven, or woven fabric (e.g., circular knitting) on the side of the porous three-dimensional nonwoven matrix that contacts the cover material 20. Such a layer of spunbond nonwoven or woven fabric can preferably have a thickness in the range of 1.0 mm or less and a basis weight in the range of 20 gsm to 200 gsm. Such spunbond nonwoven, needle-punched nonwoven, or woven fabric can preferably be manufactured from those polymer resins specified for the manufacture of the three-dimensional nonwoven matrix itself. That is, thermoplastic filaments made from polyethylene, polypropylene, metallocene-polymerized polyolefin, polyamide, or polyurethane as raw materials.

[0029]

[0034] The porous three-dimensional nonwoven matrix 14 herein can preferably be made flame-retardant. Such a flame retardant preferably includes a non-halogen-based flame retardant, and the flame retardant is preferably used at a level of up to 10.0% (by weight) in the nonwoven matrix 14. Other possible additives include antibacterial agents such as silver, copper, or zinc, and the antibacterial agent is preferably present at a level of 1.0% (by weight) to 10.0% (by weight).

[0030]

[0035] The porous three-dimensional nonwoven matrix herein also exhibits a number of other further advantages when used to replace a portion of a vehicle foam sheet. This includes, for example, that the surface of the three-dimensional nonwoven matrix herein is such that it can be mechanically adhered to the foam, thereby obviating the use of an adhesive or clip mechanism to hold the three-dimensional nonwoven matrix in place. Additionally, the three-dimensional nonwoven matrix herein can be cut to the desired thickness or shape that may be required to replace a portion of a vehicle foam seat.

[0031]

[0036] The porous three-dimensional nonwoven matrix herein can also be laminated. As described above, the porous three-dimensional nonwoven matrix herein can have a thickness in the range of 2.0 mm to 30.0 mm. Thus, for a given thickness selected within this range, such multiple three-dimensional nonwoven matrices can be laminated to provide a multi-layer three-dimensional nonwoven matrix.

Claims

1. A vehicle ventilation seat comprising a polymer foam, wherein a part of the foam is replaced by a three-dimensional nonwoven self-supporting matrix structure, and the three-dimensional nonwoven self-supporting matrix structure has (a) a thickness in the range of 2.0 mm to 30.0 mm, (b) a thickness retention rate of 50.0% to 100% at 100 lbs / ft ２ and (c) an ASTM D 737 air flow of 800 cubic feet per minute or more at 125 Pa. A vehicle ventilation seat showing the above characteristics.

2. The vehicle ventilation seat according to claim 1, wherein up to 50% of the foam is replaced by the three-dimensional non-woven self-supporting matrix structure.

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

4. The three-dimensional non-woven self-supporting matrix structure has a weight of 160.5 g / m ２ to 1017.2 g / m ２ The ventilation seat for a vehicle according to claim 1, having such a weight.

5. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure exhibits at least 70% or more of the elasticity of ASTM D 6524.

6. The three-dimensional non-woven self-supporting matrix structure exhibits a thickness retention rate of 80% or more in holding at 100 lbs / ft ２ The vehicle ventilation seat according to claim 1, which exhibits a thickness retention rate of 80% or more in holding at 100 lbs / ft

7. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure contains thermoplastic filaments.

8. The vehicle ventilation seat according to claim 2, wherein the thermoplastic filaments are selected from polyethylene, polypropylene, metallocene-polymerized polyolefin, polyamide, or polyurethane.

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

10. The foam has a polyurethane foam having a foam density of 24 kg / m ３ to 48 kg / m ３ The vehicle ventilation seat according to claim 1, comprising a polyurethane foam having a foam density of 24 kg / m to 48 kg / m

11. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure includes a spunbond non-woven fabric, a needle-punched non-woven fabric, or a knitted fabric layer having a thickness of up to 1.0 mm and a basis weight in the range of 20 gsm to 300 gsm.

12. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure contains a non-halogen flame retardant.

13. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure contains an antibacterial agent.

14. The vehicle ventilation seat according to claim 1, wherein the three-dimensional non-woven self-supporting matrix structure contains up to 5.0% of the foam embedded in the three-dimensional structure.

15. A method of forming a vehicle ventilation seat, comprising: a. providing a polymer foam configured for a vehicle seat; b. replacing a portion of the foam with a three-dimensional non-woven self-supporting matrix structure, wherein the three-dimensional non-woven self-supporting matrix structure (a) has a thickness in the range of 2.0 mm to 30.0 mm, (b) 50.0% to 100% thickness retention at 100 lbs / ft ２ and (c) exhibits an air flow of ASTM D 737 of 800 cubic feet per minute or more at 125 Pa, and the replacing.

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

17. The method according to claim 15, wherein the air flow of ASTM D 737 at 125 Pa is 800 cfm to 1360 cfm. **Claim 18** The three-dimensional non-woven self-supporting matrix structure has a weight of 160.5 g / m ２ to 1017.2 g / m ２ The method according to claim 15, having a weight of **Claim 19** The method according to claim 15, wherein the three-dimensional non-woven self-supporting matrix structure exhibits at least 70% or more of the elasticity of ASTM D 6524. **Claim 20** The three-dimensional non-woven self-supporting matrix structure exhibits a thickness retention rate of 80% or more in holding at 100 lbs / ft ２ The method according to claim 15, wherein the thickness retention rate is 80% or more in holding at 100 lbs / ft

Images