Composite fabric for vehicles

• US 6,528,437 B1
• Filed: 11/23/1999
• Issued: 03/04/2003
• Est. Priority Date: 11/23/1999
• Status: Expired due to Fees

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Blackwell, Keith M., Hepfinger, John M., Wolynes, Earle
• Primary Examiner(s): Juska, Cheryl A.
• Assistant Examiner(s): RUDDOCK, ULA CORINNA
• Application Number:
  US09/447,707
• Time in Patent Office: 1,197 Days
• Field of Search: 442/1, 442/30, 442/35, 442/38, 442/43, 442/45, 442/46, 442/49, 442/56, 442/57, 442/136, 442/141, 442/144, 442/145, 442/146, 442/315, 442/319
• US Class Current: 442/38
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2371/00 Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: Y10T 442/15 Including a foam layer
• CPC Class Codes: Y10T 442/159 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/164 Including a preformed film, foil, or sheet
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/178 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/183 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/195 Including a foam layer
• CPC Class Codes: Y10T 442/197 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/469 Including a foamed layer or component
• CPC Class Codes: Y10T 442/494 Including a nonwoven fabric layer other than paper

Abstract

The present invention is a durable composite consisting of a polyester knitted fabric and an extruded film that are heat laminated together without the use of additional adhesive. The open-mesh structure of the fabric, when combined with the film, results in improved sound dissipation for the composite as compared with conventional textile headliners. Because both the fabric and the film components have flame retardant constituents, the resulting composite is capable of meeting even the most stringent of flammability requirements. An optional backing layer may be added to the film layer to create a three-layer composite, which may be suited for certain applications.

Claims

1. A composite fabric, suitable for use in a variety of vehicles and that transmits and reflects sound waves, said composite fabric comprising a first layer, a second layer, and a third layer, wherein said first layer is comprised of an open-mesh, knitted fabric having a front side and a rear side, said knitted fabric being comprised of at least 70 denier polyester yarns, and wherein said second layer is comprised of a flame resistant, polyurethane film having a thickness of between 1 thousandth of an inch and 10 thousandths of an inch, said second layer being attached without adhesive to said front side of said knitted fabric, and wherein said third layer is affixed to said second layer and is comprised of a backing substrate selected from the group consisting of polyether foam, fiberglass batting, or non-woven polyester mat.

2. The composite of claim 1, wherein said backing substrate is polyether foam that is flame laminated onto said second layer.

3. The composite of claim 1, wherein said backing substrate is either fiberglass batting or non-woven polyester mat that is adhesive laminated onto said second layer.

4. The composite fabric of claim 1, wherein said composite fabric has a composite face side and a composite rear side, said composite face side being formed from said rear side of said knitted fabric and said composite rear side being formed from said backing substrate.