Automotive fabric composite

• US 6,632,756 B1
• Filed: 02/16/2000
• Issued: 10/14/2003
• Est. Priority Date: 02/17/1999
• Status: Expired due to Fees

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Waldrop, Anthony R., McLarty, George C., Balsa, Marc J.
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): JOHNSON, JENNA LEIGH
• Application Number:
  US09/504,831
• Time in Patent Office: 1,336 Days
• Field of Search: 442/221, 442/306, 442/308, 442/311, 442/313, 442/314, 442/315, 442/318, 297/230.1, 297/232, 297/219.1, 297/250.1, 297/218.1, 661/92
• US Class Current: 442/314
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2305/182 knitted
• CPC Class Codes: B32B 2310/0445 using gas or flames B32B2310/0427 takes precedence
• CPC Class Codes: B32B 2319/00 Synthetic rubber
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: D03D 15/56 elastic
• CPC Class Codes: D04B 21/18 incorporating elastic threads
• CPC Class Codes: Y10T 442/413 Including an elastic strand
• CPC Class Codes: Y10T 442/425 Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/444 Strand is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/456 Including additional strand inserted within knit fabric
• CPC Class Codes: Y10T 442/463 Warp knit insert strand
• CPC Class Codes: Y10T 442/469 Including a foamed layer or component
• CPC Class Codes: Y10T 442/488 Including an additional knit fabric layer

Abstract

This invention relates generally to a fabric composite for disposition across an automotive seating frame and relates more particularly to a laminated fabric incorporating elastomeric yarn which has undergone either flame or adhesive lamination so as to be joined to a knit or woven aesthetic cover by means of foam either with or without adhesive.

Claims

1. A seating support fabric composite comprised of a plurality of layers, wherein a first layer is comprised of a fabric selected from the group consisting of woven fabrics and knitted fabrics, a second layer is comprised of foam, and a third layer is comprised of a warp knit, weft insertion elastomeric fabric.

2. The fabric of claim 1 wherein said fabric is comprised of bicomponent elastomeric yarns disposed in one direction.

3. The fabric of claim 2 wherein said yarns have an elongation at break of not less than about 70 percent.

4. The fabric of claim 2 wherein said yarns have an elongation at break of not less than about 90 percent.

5. The fabric of claim 2 wherein said yarns are bicomponent elastomeric monofilament yarns having a sheath component and a core component, and wherein said sheath component has a melting point lower than that of the core component.

6. The fabric of claim 1 wherein said fabric is comprised of bicomponent elastomeric yarns disposed in more than one direction.

7. The fabric of claim 1 wherein said foam is a polyether foam that is bonded to said elastomeric fabric.

8. The fabric of claim 7 wherein said yarns are bicomponent elastomeric monofilament yarns having a sheath component has a melting point lower than that of the core component.

9. The fabric of claim 7 wherein said polyether foam is bonded by means of flame lamination.

10. A seating structure comprised of a frame to which is attached the seating support fabric composite of claim 8.

11. The seating structure of claim 10 wherein said fabric is disposed in tension over said frame.