Ventilated vehicular seat

Abstract

A ventilated vehicular seat which has the ability to compress and recover while having good airflow performance that offers vehicle seat cooling and heating performance. The ventilated vehicular seat comprises a three-dimensional mat of extruded entangled filaments having a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft² of 50.0% to 100%.

Description

VENTILATED VEHICULAR SEATFIELD

[0001] The invention pertains to ventilated vehicular seats.BACKGROUND

[0002] Vehicular seats, in particular car seats, are generally formed from a major part of polymeric foam cushions, such as for example polyurethane foam cushions. The foam cushions defining the shape of the vehicular seat are generally covered by a surface material to provide an appealing look and touch to a vehicle passenger.

[0003] Vehicular seats may be configured with active heating and / or active cooling, while being under compression by a vehicle passenger sitting on the vehicular seat.

[0004] Knitted fabrics and / or reticulated foams have been reported for use as spacer fabrics, in vehicle seat trim covers and through / around foam cushions. The spacer fabric is reference to the feature that such material allows for airflow for seats, and in particular in seats configured with active cooling or active heating while being under compression. The materials are therefore targeted to allow for air to pass through their construction and provide for cooling and heating. A static air space may be desirable to provide insulation.

[0005] A need nevertheless remains for three-dimensional materials for a vehicular seat that is easy to form into a desired shape and has the ability to compress and recover along with good airflow performance that may offer vehicle seat cooling and heating performance.SUMMARY

[0006] A ventilated vehicular seat is provided comprising a support material configured for said vehicular seat, wherein a portion of said a support material includes a three-dimensional mat of extruded entangled filaments, wherein the three-dimensional mat of extruded entangled filaments has a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft2of 50.0% to 100%.

[0007] The support material comprised in the vehicular seat is contemplated to be foam as well as a three-dimensional fabric or any other three-dimensional material, which may be used as a foam replacement.

[0008] The ventilated vehicular seat may in some embodiments achieve cooling and / or heating performance.

[0009] In some embodiments, the ventilated vehicular seat may have an ASTM D737 airflow at 125 Pa of greater than or equal to 800 cubic feet per minute enables to provide sufficient air flow for active cooling and / or active heating while being compressed, for example by a vehicle passenger, and to recover after the vehicle passenger is no longer engaged with the vehicular seat.

[0010] The ventilated vehicular seat comprising a three-dimensional mat of extruded entangled filaments may reduce, or avoid completely, the need for a reticulation process step that is necessary to enhance air flow in foams for prior art vehicular seats.

[0011] The three-dimensional mat of extruded entangled filaments may be attached to a foam material utilized in the ventilated vehicular seat or may replace at least a portion of foam material as compared to prior art ventilated vehicular seats formed (mainly) of polymeric foam cushions.

[0012] The ventilated vehicular seat may be assembled together from at least two parts including at least a three-dimensional mat of extruded entangled filaments, and at least one other part which may be selected from a polymeric foam, a three-dimensional woven fabric, a further three- dimensional mat of extruded entangled filaments, or any other three-dimensional material that allows for compression and recovery, which contemplates the use of any three-dimensional material that provides some elastic recovery to a compression force. A three-dimensional material that allows for compression and recovery may be used as a foam replacement. The at least three- dimensional mat of extruded entangled filaments preferably improves the elastic recovery of the ventilated vehicular seat.

[0013] The ventilated vehicular seat may for example be assembled together from at least two parts including the three-dimensional mat of extruded entangled filaments and one or more parts of a foam. The ventilated vehicular seat may for example also be assembled together from several parts including the three-dimensional mat of extruded entangled filaments and one or more further three-dimensional mats of extruded entangled filaments. The ventilated vehicular seat may for example also be assembled together from several parts including the three-dimensional mat of extruded entangled filaments, one or more parts of a foam and one or more further three- dimensional mats of extruded entangled filaments.

[0014] The ventilated vehicular seat may alternatively be formed by providing a support material configured for a vehicular seat wherein said support material includes a location to receive a three-dimensional mat of extruded entangled filaments; positioning at said location in the support material said three-dimensional mat of extruded entangled filaments, wherein the three- dimensional of extruded entangled filaments has a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft2of 50.0% to 100%, and optionally one or more further three-dimensional mats of extruded entangled filaments.

[0015] In some embodiments, the support material may be a polymeric foam.

[0016] The location in the support material for receiving the three-dimensional mat of extruded entangled filaments can be achieved in variety of ways, such as forming the support material with a void location to receive the three-dimensional mat of extruded entangled filaments or removing a portion of the support material to receive the three-dimensional mat of extruded entangled filaments, wherein such removal may be achieved by a variety of techniques, such as mechanical removal such as cutting or foam ablation.

[0017] The location in the support material for receiving the three-dimensional mat of extruded entangled filaments can also be achieved by forming a polymeric foam in the presence of the three- dimensional mat of extruded filaments, such that the three-dimensional mat is then positioned at a location within the foam.

[0018] The three-dimensional mat of extruded entangled filaments may be attached to a foam material utilized in the ventilated vehicular seat or may replace at least a portion of foam material as compared to prior art ventilated vehicular seats formed (mainly) of polymeric foam cushions.

[0019] The three-dimensional mat of extruded entangled fdaments preferably contains 5.0% by weight or less of embedded foam within the three-dimensional mat of extruded entangled filaments, and more preferably 3.0 % by weight or less of embedded foam, and even more preferably 2.0 % by weight or less, and finally, three-dimensional mat of extruded entangled filaments preferably does not contain any embedded foam material, wherein the term embedded is understood to have been fulfilled when the foam material has penetrated into the three-dimensional mat of extruded entangled filaments by at least 0.5 mm, when the three-dimensional mat of extruded entangled is not subjected to an external load.

[0020] The three-dimensional mat of extruded entangled filaments preferably is self-supporting, which is reference to the feature that the three-dimensional mat of extruded entangled filaments can support itself under its own weight, can provide requisite cushioning and define air passageways in the ventilated vehicular seat. The three-dimensional mat of extruded entangledfilaments may also serve to reinforce a foam material in the ventilated vehicular seat, when replacing a portion of a foam material in the ventilated vehicular seat.

[0021] The ventilated vehicular seat may comprise a surface material covering the three- dimensional mat of extruded entangled filaments on at least one side to provide an appealing look and touch to a vehicle passenger. Suitable surface materials include for example be a woven fabric, a leather, or an artificial leather.

[0022] The filaments of the three-dimensional mat of extruded entangled filaments may preferably be comprise extruded polymeric filaments.

[0023] The three-dimensional mat of extruded entangled filaments may be formed by providing extruded filaments and collecting the extruded filaments into a three-dimensional structure by allowing the extruded filaments to bend and to come into contact with each other, preferably in a molten state.

[0024] The three-dimensional mat of extruded entangled filaments may be a three-dimensional random mat of extruded entangled filaments. Bending of the extruded filaments can for example be initiated by collecting the filaments into a water bath, wherein the bending of the extruded filaments is random and does not result in an array of particular three-dimensional form.

[0025] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat may advantageously be a three-dimensional structured mat of extruded entangled filaments. Bending and entangling of the extruded filaments are preferably initiated by collecting the filaments onto a profiled surface, which defines the structure of the three-dimensional structured mat of extruded entangled filaments.

[0026] The three-dimensional mat of extruded entangled filaments may be provided by extruding polymeric filaments and collecting the extruded filaments into a three-dimensional (3D) structure by allowing the filaments to bend, to entangle and come in contact with each other, preferably in the molten state. The filaments of the three-dimensional mat of extruded entangled filaments herein may preferably be thermally bonded at their crossing points.

[0027] The bending and entangling of the extruded filaments may be initiated by collecting the extruded filaments onto a profiled surface, which then can define the three-dimensional structured mat of extruded entangled filaments herein.

[0028] The three-dimensional structured mat of extruded entangled filaments may be formed in any desired three-dimensional (3D) form, preferably in a series of three-dimensional sub-structures, such as for example a series of U-grooves or V-grooves, or a series of hills and valleys, hemispheres, positive and / or negative cuspates, cups and / or waffles, pyramids, cones and / or cylinders capped with a hemisphere, either being spaced apart by a specified distance or abutted to each other, and either being placed in parallel lines or in staggered formation. The thickness of the three-dimensional structured mat of extruded entangled filaments is determined by two planes being defined by the apexes of the three-dimensional sub-structures.

[0029] The three-dimensional mat of extruded entangled filaments may comprise a thickness gradient across the three-dimensional mat of extruded entangled filaments, in particular when the three-dimensional mat of extruded entangled filaments is formed by collecting the extruded filaments onto a profiled surface. When the profiled surface exhibits a height gradient, then the three-dimensional mat of extruded entangled filaments will be formed having a thickness gradient, which enables to provide a seat cushion or a back cushion with a thickness gradient, for example to provide improved support for the passenger engaged with the vehicular seat. The thickness gradient of the three-dimensional mat of extruded entangled filaments may have a ratio of a maximum thickness over a minimum thickness of at least 1.05. The ratio of the maximum thickness over the minimum thickness may be at least 1.10, or at least 1.20, or at least 1.30.

[0030] The three-dimensional mat of extruded entangled filaments may intentionally be flat without apexes of three-dimensional sub-structures on one side of the three-dimensional structured mat of extruded entangled filaments. Such a three-dimensional structured mat of extruded entangled filaments being intentionally flat on one side is also referred to as flat back.

[0031] The ratio of the weight of the material in the three-dimensional sub-structures (bulk) and on the intentionally flat surface (flat back) may be varied. The ratio of the weight of the material in the three-dimensional sub-structures and on the intentionally flat surface may range from 20:80 to 80:20, or range from 30:70 to 70:30, or range from 40:60 to 60:40. The three-dimensional structured mat of extruded entangled filaments being intentionally flat on one side may for example comprise 75% of the weight of the material in the three-dimensional sub-structures and 25% of the weight on the intentionally flat surface. The three-dimensional structured mat of extruded entangled filaments being intentionally flat on one side may for example comprise 60% of the weight of the material in the three-dimensional sub-structures and 40% of the weight on the intentionally flat surface.

[0032] The intentionally flat surface in the flat back may be a two-dimensional mat of extruded entangled filaments, wherein the filaments preferably are extruded mono-component filaments. The two-dimensional mat of extruded entangled filaments may be provided by any suitable process. Preferably, the two-dimensional structured mat of extruded entangled filaments is provided by extruding polymeric filaments and collecting the extruded filaments onto a two- dimensional flat surface by allowing the filaments to bend, to entangle and to come into contact with each other, preferably in a still molten state. Bending and entangling of the extruded filaments are preferably initiated by collecting the filaments onto a flat surface, which defines the flat structure of the two-dimensional mat of extruded entangled filaments.

[0033] The filaments comprised in the two-dimensional mat of extruded entangled filaments may have the same diameter as the filaments comprised in the three-dimensional mat of extruded entangled filaments.

[0034] The two-dimensional mat of extruded entangled filaments and the three-dimensional mat of extruded entangled filaments of the flat back may be formed separately and subsequently attached to each other, for example by applying a glue, but preferably thermal bonding.

[0035] The two-dimensional mat of extruded entangled filaments and the three-dimensional mat of extruded entangled filaments of the flat back may also be formed integrally. The filaments may be simultaneously extruded from a single spinneret wherein a selection of extruded filaments is collected onto a profiled surface to from the three-dimensional mat of extruded entangled filaments and a selection of extruded filaments is collected onto a two-dimensional flat surface to form the two-dimensional mat of extruded entangled filaments. The two-dimensional mat of extruded entangled filaments and the three-dimensional mat of extruded entangled filaments are preferably directly brought into contact with other before the filaments are fully cooled down to obtain a thermally bonded flat back.

[0036] The three-dimensional structured mat of extruded entangled filaments being intentionally flat on one side may comprise a further material layer connected to the other side of the three- dimensional structured mat of extruded entangled filaments. The further material layer may be a non-woven, a woven fabric, a knit fabric, for example a circular knit, a spacer fabric, or a film.

[0037] The non-woven of the further material layer may be any type non-woven, including a V- lapped nonwoven, an airlaid non-woven, a spunbonded or spun laid non-woven, a meltblown nonwoven, a carded non-woven, and a wetlaid non-woven. The respective non-woven may bemechanically bonded, for example by needle-punching or hydroentanglement, chemically bonded, and / or thermally bonded, or example by calendaring, through air bonding or ultrasonic bonding.

[0038] The ventilated vehicular seat may comprise the three-dimensional mat of extruded entangled filaments being intentionally flat without apexes of three-dimensional sub-structures on one side of the three-dimensional structured mat of extruded entangled filaments in orientation wherein the side being intentionally flat is directed towards the passenger engaging with the vehicular seat.

[0039] The filaments comprised in the three-dimensional mat of extruded entangled filaments herein may be macroscopic filaments. The macroscopic fdaments may have an average diameter of 100 m to 2000 pm, more preferably in the range of 200 pm to 1500 pm, even more preferably in the range of 300 pm to 1100 pm, and most preferably in the range of 500 pm to 900 pm.

[0040] The three-dimensional mat of extruded entangled filaments herein is preferably selected from a mat of extruded entangled filaments wherein the filaments are fused at their intersections.

[0041] Preferably, the extruded entangled filaments are thermoplastic filaments comprising or consisting of polyolefin polymer, including polyethylene, polypropylene and metallocene polymerized polyolefin, polyamide polymer, polyester polymer, including polyethylene terephthalate, polybutylene terephthalate and polytrimethylene terephthalate, polyether polymer, or polyurethane polymer.

[0042] In an embodiment, the extruded entangled filaments comprise or consist of one or more polyamides. For example, the three-dimensional mat of extruded entangled filaments may be an Enkamat® nylon mat available from Low & Bonar Inc. (Enka, N.C.).

[0043] The extruded entangled filaments may also comprise or consist of thermoplastic elastomeric polymer, including thermoplastic polyolefin elastomeric polymers (TPO, including EPDM - Ethylene Propylene Diene Monomer), such as for example thermoplastic polypropylene elastomeric polymer, thermoplastic vulcanisates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrenic elastomeric polymers (TPS, including styrene-butadiene copolymers (SBC), such as for example SBS, SEBS, SEPS, SEEPS and MBS, thermoplastic polyamide polymers (TPA), or thermoplastic elastomeric polyurethane polymers (TPU).

[0044] The thickness of the three-dimensional mat of extruded entangled filaments may be varied, but the thickness is at least 2.0 mm, as determined in accordance with ASTM D 6525 at a pressureof at least 2 kPa. The thickness of the three-dimensional mat of extruded entangled filaments may be at least 5 mm, or at least 10 mm, or at least 20 mm, or at least 40 mm, or at least 60 mm, or at least 80 mm, or at least 100 mm. The thickness of the three-dimensional mat of extruded entangled filaments may be at most 200 mm, or at most 150 mm, or at most 125 mm, or at most 100 mm, or at most 80 mm, or at most 60 mm, or at most 50 mm, or at most 40 mm, or at most 30 mm.

[0045] The thickness of the three-dimensional mat of extruded entangled filaments may preferably be in the range of 2.0 mm to 30.0 mm, including all individual values and increments therein. For example, in a particularly preferred embodiment, the three-dimensional mat of extruded entangled filaments 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.

[0046] The three-dimensional mat of extruded entangled filaments preferably has a relatively consistent thickness, which is reference to the feature that the thickness does not vary by more than + / - 1.0 mm, or + / - 0.5 mm, or + / - 0.1 mm.

[0047] By way of example, three-dimensional mat of extruded entangled filaments may preferably have a thickness of 15.0 mm, and may not vary in thickness by more than + / - 1.0 mm, or + / - 0.5 mm, or + / - 0.1 mm.

[0048] The three-dimensional mat of extruded entangled filaments in the ventilated vehicular seat has an ASTM D737 airflow at 125 Pa of at least 800 cfm. The ASTM D737 airflow at 125 Pa may be at least 1000 cfm, or at least 1200 cfm, or at least 1400 cfm. The ASTM D737 airflow at 125 Pa may be at most 3000 cfm, or at most 2500 cfm, or at most 2000 cfm.

[0049] In an embodiment, the ASTM D737 airflow at 125 Pa may be in the range of 800 cfm to 1360 cfm.

[0050] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat may have a weight in the range of 2.95 to 44.25 ounces per square yard, i.e. may have a weight of 100 g / m2to 1500 g / m2, preferably a weight of 300 g / m2to 800 g / m2, or more preferably 300 g / m2to 400 g / m2.

[0051] In an embodiment, the three-dimensional mat of extruded entangled filaments in the ventilated vehicular seat may have a weight in the range of 5 ounces per square yard (160.5 g / m2) to 30.0 ounces per square yard (1017.2 g / m2), including all individual values and increments therein, in particular for a thickness of the three-dimensional mat of extruded entangled filaments of 2.0 mm to 30.0 mm.

[0052] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat may have an open area of at least 75 vol.%, preferably at least 90 vol.%, more preferably at least 95 vol.%. The ventilated vehicular seat comprising the three-dimensional mat of extruded entangled filaments may contribute to weight reduction, in particular due to the open area of the three-dimensional mat of extruded entangled filaments.

[0053] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat may have a resiliency under ASTM D6524 of at least 70% or more, more preferably in the range of 70% to 90%, including all individual values and increments therein, in particular when the three-dimensional mat of extruded entangled filaments has an open area of at least 90 vol.%.

[0054] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat may have a compression set according to DIN EN ISO 1856 of at most 45%, or at most 40%, or at most 35%, or at most 30%, or at most 25%, after 72 hours 50% deformation at room temperature.

[0055] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat preferably has a maximum load tensile strength, in the machine direction (direction of the three-dimensional mat of extruded entangled filaments as it is produced), in the range of 20 to 60 pounds 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 percent determined using the ASTM D6818 method tested at 12 inches per minute, gage length of 3 inches and 4 inch wide specimen.

[0056] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat also preferably has a maximum load tensile strength in the cross-direction (perpendicular direction across the three-dimensional mat of extruded entangled filaments as it is produced) in the range of 40 to 120 pounds force, 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 percent determined using the ASTM D6818 method tested at 12 inches per minute, gage length of 3 inches and 4 inch wide specimen.

[0057] The three-dimensional mat of extruded entangled filaments comprised in the ventilated vehicular seat preferably provides an indentation force deflection, according to ASTM D357B, on a 4.0 inch sample, at 25% deflection, of 42 lbs to 55 lbs. In addition, the three-dimensional mat ofextruded entangled filaments herein has a thickness retention at 100 Ibs / square foot of 50.0% to 100%, or a thickness retention at 200 Ibs / square foot of 25.0% to 95.0%.

[0058] As mentioned, the ventilated vehicular seat may comprise one or more further three- dimensional mats of extruded entangled filaments, in addition to the three-dimensional mat of extruded entangled filaments, which means that the ventilated vehicular seat may comprise two or more three-dimensional mats of extruded entangled filaments. Each of the one or more further three-dimensional mats of extruded entangled filaments may be designed independently, regarding the variations and properties of the three-dimensional mat of extruded entangled filaments disclosed herein. For example, each of the one or more further three-dimensional mats may have the same or a different thickness, filament diameter, weight, polymer type, three-dimensional (3D) form, and / or thickness gradient as the three-dimensional mat of extruded entangled filaments disclosed herein.

[0059] The one or more further three-dimensional mats of extruded entangled filaments may be comprised at different locations in the ventilated vehicular seat.

[0060] The ventilated vehicular seat may comprise a stack of the three-dimensional mat of extruded entangled filaments and one or more further three-dimensional mats of extruded entangled filaments. As noted herein above, the three-dimensional mat of extruded entangled filaments has a thickness of at least 2.0 mm. Accordingly, for a given thickness, a plurality of such three-dimensional mats of extruded entangled filaments may be stacked to provide a multi-layered structure of two or more three-dimensional mats of extruded entangled filaments.

[0061] The ventilated vehicular seat may comprise an intermediate layer between the three- dimensional structured mat of extruded entangled filaments and a further three-dimensional mat of extruded entangled filaments, to prevent that the three-dimensional structured mat of extruded entangled filaments and the further three-dimensional mat of extruded entangled filaments become nested into each other.

[0062] In addition, the three-dimensional mat of extruded entangled filaments herein can employ the three-dimensional structured mat that is described in WO2018 / 206568, whose teachings are incorporated by reference.

[0063] The ventilated vehicular seat may be composed for at least 50 wt.% of one or more three- dimensional mats of extruded entangled filaments. Preferably, the ventilated vehicular seat may be comprised for at least 60 wt.%, or at least 70 wt.%, or at least 80 wt.%, or at least 90 wt.%, ofone or more three-dimensional mats of extruded entangled filaments. In the determination of the volume percentage, the surface material is excluded.

[0064] In an embodiment, the ventilated vehicular seat may consist of one or more three- dimensional mats of extruded entangled filaments.

[0065] The ventilated vehicular seat comprising a three-dimensional mat of extruded entangled filaments or consisting of one or more three-dimensional mats of extruded entangled filaments enables to lower emissions as compared to prior art vehicular seats formed for a major part of polyurethane foam cushions.

[0066] The content of foam in a vehicular seat can advantageously be reduced, or even avoided completely by the three-dimensional mats of extruded entangled filaments, as there is a demand for more sustainable cushioning structures as compared to foams, and in particular polyurethane foams, which are difficult to recycle.BRIEF DESCRIPTION OF THE DRAWINGS

[0067] FIG. 1 is a cross-sectional view of a portion of a vehicle seating wherein portions of the foam are replaced by an insert of a three-dimensional mat of extruded entangled filaments.

[0068] FIG. 2A is another cross-sectional view of a portion of the vehicle seating wherein a three- dimensional mat of extruded entangled filaments replaces a portion of the foam in the lower portion of the vehicle seating.

[0069] FIG. 2B is another cross-sectional view of a portion of the vehicle seating wherein a three- dimensional mat of extruded entangled filaments replaces a portion of the foam in the lower portion of the vehicle seating, where the weight of the passenger engaged with the vehicle seating is illustrated.

[0070] FIG. 3A is another cross-sectional view of a portion of the vehicle seating wherein a three- dimensional mat of extruded entangled filaments replaces a portion of the foam in the lower portion of the vehicle seating, which illustrates the preferred position of the HVAC system fan.

[0071] FIG. 3B is another cross-sectional view of a portion of the vehicle seating wherein a three- dimensional mat of extruded entangled filaments replaces a portion of the foam in the lower portion of the vehicle seating, which illustrates how the weight of a typical passenger does not interfere with the operation of the HVAC system fan.

[0072] FIG. 4 provides another cross-sectional view of a vehicle seating illustrating how the three- dimensional mat of extruded entangled filaments provides airflow passageways in the vehicle seating.DETAILED DESCRIPTION

[0073] The three-dimensional mat of extruded entangled filaments is contemplated to be particularly suitable in air-cooled and / or air-heated vehicular seating. As illustrated in FIG. 1, which is a cross-sectional view of a portion of the vehicle seating 10, foam portions are identified at 12 and the insert of the three-dimensional mat of extruded entangled filaments appears as item 14. As can be seen, the insert 14 of the three-dimensional mat of extruded entangled filaments replaces a portion of the foam and preferably contains 5.0% by weight or less of embedded foam within the three-dimensional mat of extruded entangled filaments, and even more preferably, 3.0 % by weight or less of embedded foam, and even more preferably 2.0 % by weight or less, and finally, three-dimensional mat of extruded entangled filaments preferably does not contain any embedded foam.

[0074] The vehicle HVAC system fan 16 is then able to drive cool air or warm air through the three-dimensional mat of extruded entangled filaments 14 at a preferred airflow rate greater than or equal to 800 cubic feet per minute (cfm), as measured by ASTM D737 at 125 Pa. More preferably, the airflow is in the range of 800 cfm to 1360 cfm. As also illustrated, one can preferably include a spacer layer 18 of a further three-dimensional mat of extruded entangled filaments under the cover stock layer 20. The spacer layer 18 itself may have a preferred thickness in the range of 3.0 mm to 20.0 mm and may provide a similar airflow rate in the range of 800 cfm to 1360 cfm. The HVAC system fan 16 is therefore able to drive cool air or warm air through the three-dimensional mat of extruded entangled filaments 14 and the spacer layer 18 and then through the cover stock layer 20 as may be set by a vehicle passenger when implementing the vehicle HVAC system 16.

[0075] FIGS. 2A and 2B illustrate again in cross-section a view of a portion of the vehicle seating, wherein the three-dimensional mat of extruded entangled filaments 14 inserts and replaces a portion of a foam 12 in the lower portion of a vehicle seating. As may now be appreciated, the three-dimensional mat of extruded entangled filaments 14 can otherwise function as a duct, channel or tunnel for the flow of cool air or warm air driven by the vehicle HVAC system fan 16.

[0076] FIG. 2B illustrates in cross-section the vehicle seating of FIG. 2A, where a passenger has engaged with the vehicle seating and placed his / her weight thereon. The cover stock 20 and spacer layer 18 are not shown for clarity. As can be observed, while a portion of the foam 12 may compress, the three-dimensional mat of extruded entangled filaments 14 preferably does not compress or indicates the thickness retention noted herein, and the ability of the three-dimensional mat of extruded entangled filaments 14 to compress and recover along with relatively enhanced airflow performance is preserved so that it may continue to provide pathways in the form of a duct, channel or tunnel for the flow of cool air or warm air.

[0077] It should be appreciated that in the absence of the three-dimensional mat of extruded entangled filaments 14, the weight of the passenger would otherwise cause the foam to compress, and the deformed foam would then reduce any cut-out space in the foam for the flow of air. The ability of the three-dimensional mat of extruded entangled filaments to provide limited compression under the weight of a typical passenger (50 lbs to 300 lbs) thus provides a more efficient vehicle seating configuration, at relatively lighter overall weight, that also preserves the efficiency of the HVAC system when operating within the vehicle. In such context, for a given thickness of the three-dimensional mat of extruded entangled filaments herein is one that indicates a thickness retention at 100 lbs / ft2pressure of 50-100%, or a thickness retention at 200 lbs / ft2of 25% to 95%.

[0078] Table 1 below shows the thickness retention under pressure for three-dimensional mats of extruded entangled filaments herein:Table 1: Thickness Retention

[0079] In Table 1, FB indicates flat back, meaning that the back of the three-dimensional mat of extruded entangled filaments is intentionally flat without peaks. The reference to 75 / 25 identifies that 75% of the weight of the material is in the bulk and 25% on the surface (flat back). The reference to 60 / 40 indicates that 60% of the weight of the three-dimensional mat of extruded entangled filaments is in the bulk and 40% on the surface (flat back). As can be seen from the above thickness retention evaluation, the three-dimensional mat of extruded entangled filaments herein more preferably retains 80.0% more of its thickness at 100 lbs / ft2and 65.0% or more of its thickness at 200 lbs / ft2. The pressure was applied onto the intentionally flat side of the flat back.

[0080] FIG. 3A and 3B are similar to FIG. 2A and 2B and show the additional feature of a preferred position of the HVAC system fan 16 within a cut-out region of the three-dimensional mat of extruded entangled filaments 14. As can be seen from FIGS. 3A and 3B, when a vehicle passenger engages with the vehicle seating, the three-dimensional mat of extruded entangled filaments again preferably does not fully compress and deform under the weight of a typical passenger (50 lbs to 300 lbs) and the HVAC system fan 16 is not compromised due to the presence of some compressed foam interfering with its operation.

[0081] FIG. 4 provides another view as to how the three-dimensional mat of extruded entangled filaments 14 may be comprised within the vehicle seating to more effectively provides pathwaysin the seat cushion in the form of a duct, channel or tunnel for the flow of cool air or warm air. As now shown in FIG. 4, such pathways may be positioned in both the vehicle seat backing 18 and seat cushion where the three-dimensional mat of extruded entangled filaments 14 is inserted in the foam 12. Accordingly, it may be appreciated that one or a plurality of airflow pathways may now be provided within a seat cushion comprising foam 12 by use of the three-dimensional mat of extruded entangled filaments 14 herein to provide for circulation of warm air or cool air with a reduction in weight and wherein such pathways are not compromised when a passenger is engaged with the vehicle seating, due to compression resistance. As noted above, the flow of air delivered at the seat back 20 or at the surface 22 of the seat cushion preferably is maintained and may fall in the preferred range of 800 cfm to 1360 cfm.

[0082] Expanding on the above, it is more specially contemplated that the three-dimensional mat of extruded entangled filaments 14 herein when used in vehicle foam seating, while providing the above referenced pathways for airflow, can also provide mechanical property features that are similar to the foam 12 that is employed, while also providing the aforementioned compression resistance.

[0083] For example, the foam may be partly or completely replaced by the three-dimensional mat of extruded entangled filaments 14. Typical polyurethane foams which can be reduced or avoided to be used may have a density of at least 10 kg / m3. Typical polyurethane foams which can be reduced or avoided to be used may have a density of at most 10 kg / m3. Typical polyurethane foams which can be reduced or avoided to be used may have a density of 24 to 48 kg / m3.

[0084] Typical polyurethane foams which can be reduced or avoided to be used may have foam indentation force deflection (IFD) of 25 to 70 pounds force per 50 inches, a thickness retention in the range of 85% to 93% at 100 lbs / ft2and / or a thickness retention in the range of 25% to 55% at 500 lbs / ft2.

[0085] By reference to (a portion of) the polyurethane foam being replaced, it is contemplated herein that in an embodiment up to 50% by weight of the preferred polyurethane foam utilized in the cushioning and seat-back may be replaced by the three-dimensional mat of extruded entangled filaments. Accordingly, 1% by weight to 50% by weight of the polyurethane foam in the seat cushion and / or seat-back may be replaced by the three-dimensional mat of extruded entangled filaments herein, including all values and increments therein. For example, one may replace 10% to 50% by weight of the foam, or 20% to 50% by weight of the foam, or 30% to 50% by weightof the foam, or 40% to 50% by weight of the foam with the three-dimensional mat of extruded entangled filaments herein.

[0086] The ventilated vehicular seat may also comprise a three-dimensional mat of extruded entangled filaments to partly or completely replace spacer fabrics. The ventilated vehicular seat comprising the three-dimensional mat of extruded entangled filaments may enable to lower fiber fragment loss upon cutting as compared to prior art spacer knit fabrics.

[0087] It is further contemplated herein that the ventilated vehicular seat may comprise an additional layer of material connected to a side of the three-dimensional mat of extruded entangled filaments, which may advantageously be orientated towards a cover stock.

[0088] The additional layer of material may be a non-woven, a woven fabric, a knit fabric, for example a circular knit, a spacer fabric, or a film.

[0089] The non-woven may be any type non-woven, including a V-lapped nonwoven, an airlaid non-woven, a spunbonded or spun laid non-woven, a meltblown non-woven, a carded non-woven, and a wetlaid non-woven. The respective non-woven may be mechanically bonded, for example by needle-punching or hydroentanglement, chemically bonded, and / or thermally bonded, or example by calendaring, through air bonding or ultrasonic bonding.

[0090] The additional layer of material, in particular a non-woven or a woven fabric, may preferably have a thickness in the range of up to and including 1.0 mm and / or a basis weight in the range of 20 g / m2to 200 g / m2as determined in accordance with ISO 9073-2.

[0091] The additional layer of material may preferably be made of those polymeric resins identified for the manufacture of the three-dimensional mat of extruded entangled filaments itself, which may preferably comprise or consist of thermoplastic filaments comprising or consisting of polyolefin polymer, including polyethylene, polypropylene and metallocene polymerized polyolefin, polyamide polymer, polyester polymer, including polyethylene terephthalate, polybutylene terephthalate and poly trimethylene terephthalate, polyether polymer, or polyurethane polymer, or which may comprise or consist of thermoplastic elastomeric polymer, including thermoplastic polyolefin elastomeric polymers (TPO, including EPDM - Ethylene Propylene Diene Monomer), such as for example thermoplastic polypropylene elastomeric polymer, thermoplastic vulcanisates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrenic elastomeric polymers (TPS, including styrene-butadienecopolymers (SBC), such as for example SBS, SEBS, SEPS, SEEPS and MBS, thermoplastic polyamide polymers (TPA), or thermoplastic elastomeric polyurethane polymers (TPU).

[0092] The three-dimensional mat of extruded entangled filaments 14 herein may preferably be made flame retardant by one or more flame retardants. Such flame retardants preferably include non-halogenated flame retardants, which are preferably employed in the three-dimensional mat of extruded entangled filaments 14 at a level of up to 10.0 wt.%. The flame retardants may be incorporated within the filaments of the three-dimensional mat of extruded entangled filaments, or may be applied onto the surface of filaments of the three-dimensional mat of extruded entangled filaments. Other contemplated additives comprised in or on the three-dimensional mat of extruded entangled filaments include antimicrobial agents, such as for example silver, copper or zinc, which are preferably employed at a level of 1.0 wt.% to 10.0 wt.%.

[0093] The three-dimensional mat of extruded entangled filaments herein also indicates a number of other additional advantages when used in a vehicle seating, in particular to replace (a portion of) the foam in the vehicle seating. This includes, e.g., that the surface of the three-dimensional mat of extruded entangled filaments herein is such that it can mechanically adhere to the foam thereby obviating the use of adhesives or clip mechanisms to hold the three-dimensional mat of extruded entangled filaments in place. In addition, the three-dimensional mat of extruded entangled filaments herein can be cut to a desired thickness or shape as may be necessary to replace (a portion of) the foam in the vehicle seating.

Claims

What is claimed is:

1. A ventilated vehicular seat comprising a support material configured for said vehicular seat, wherein a portion of said support material includes a three-dimensional mat of extruded entangled filaments, wherein the three-dimensional of extruded entangled filaments has a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft2of 50.0% to 100%.

2. The ventilated vehicular seat according to claim 1, wherein the three-dimensional mat of extruded entangled filaments has an ASTM D737 airflow at 125 Pa of greater than or equal to 800 cubic feet per minute.

3. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments is a three-dimensional structured mat of extruded entangled filaments.

4. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the at least one three-dimensional mat of extruded entangled filaments has a basis weight of 100 g / m2to 1500 g / m2.

5. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat comprises one or more further three-dimensional mats of extruded entangled filaments.

6. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat is composed for at least 50 wt.% of one or more three-dimensional mats of extruded entangled filaments.

7. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments has an ASTM D 6524 resiliency of at least 70% or more.

8. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments has a thickness retention at retention at 100 lbs / ft2of 80% or more.

9. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the extruded filaments comprise a thermoplastic polymer.

10. The ventilated vehicular seat according to claim 9, wherein the thermoplastic polymer is a polyolefin polymer, a polyamide polymer, a polyester polymer, a polyether polymer, or a polyurethane polymer.

11. The ventilated vehicular seat according to any one or more of claims 1 to 9, wherein the extruded filaments comprise a thermoplastic elastomeric polymer.

12. The ventilated vehicular seat according to claim 11, wherein the thermoplastic elastomeric polymer is a thermoplastic polyolefin elastomeric polymer, a thermoplastic vulcanisate, a thermoplastic polyester elastomeric polymer, a thermoplastic styrenic elastomeric polymer, a thermoplastic polyamide polymer, or a thermoplastic elastomeric polyurethane polymer.

13. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the extruded filaments have a diameter in the range of 100 pm to 2000 pm.

14. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat comprises a stack of the three-dimensional mat of extruded entangled filaments and one or more further three-dimensional mats of extruded entangled filaments.

15. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat comprises a polymeric foam.

16. The ventilated vehicular seat according to claim 15, wherein the polymeric foam is a polyurethane foam.

17. The ventilated vehicular seat according to any one or more of claims 15 to 16, wherein the foam has a density of 24 kg / m3 to 48 kg / m3.

18. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat comprises a cover stock.

19. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the ventilated vehicular seat comprises an additional layer of material connected to a side of the three-dimensional mat of extruded entangled filaments.

20. The ventilated vehicular seat according to claim 19, wherein the additional layer of material is a non-woven, a woven fabric, a knit fabric, for example a circular knit, a spacer fabric, or a film.

21. The ventilated vehicular seat according to any one or more of claims 19 to 20, wherein the additional layer of material has a thickness in the range of up to and including 1.0 mm and / or a basis weight in the range of 20 g / m2to 200 g / m2.

22. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments comprises a non-halogenated flame retardant.

23. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments comprises an antimicrobial agent.

24. The ventilated vehicular seat according to any one or more of the preceding claims, wherein the three-dimensional mat of extruded entangled filaments comprises 5.0% or less of foam embedded within the three-dimensional mat of extruded entangled filaments.

25. A method of forming a ventilated vehicle seat comprising:assembling at least two parts together to provide a support material configured for said vehicular seat, including at least a three-dimensional mat of extruded entangled filaments, and at least one other part, selected from a polymeric foam, a three-dimensional woven fabric or any other three-dimensional material that allows for compression and recovery, wherein the three- dimensional of extruded entangled filaments has a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft2of 50.0% to 100%.

26. A method of forming a ventilated vehicle seat comprising: providing a support material configured for a vehicular seat, wherein said support material includes a location to receive a three-dimensional mat of extruded entangled filaments; positioning at said location in the support material said three-dimensional mat of extruded entangled filaments, wherein the three-dimensional of extruded entangled filaments has a thickness of at least 2.0 mm, and a thickness retention at 100 lbs / ft2of 50.0% to 100%.

27. The method according to any one or more of claims 25 to 26, wherein the ventilated vehicular seat comprises one or more further three-dimensional mats of extruded entangled filaments.

28. The method according to any one or more of claims 26 to 27, wherein the ventilated vehicular seat is composed for at least 50 wt.% of one or more three-dimensional mats of extruded entangled filaments.

29. The method according to any one or more of claims 26 to 28, wherein the three-dimensional mat of extruded entangled filaments has an ASTM D 6524 resiliency of at least 70% or more.

30. The method according to any one or more of claims 26 to 29, wherein the three-dimensional mat of extruded entangled filaments has a thickness retention at retention at 100 lbs / ft2of 80% or more.

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