US 2003O176127A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2003/0176127 A1
McCabe et al. (43) Pub. Date: Sep. 18, 2003
(54) COMPOSITE FOR USE IN THE Related U.S. Application Data
MANUFACTURE OF TRANSPORTATION
VEHICLE SEATING TRIM (63) Continuation of application No. 09/504.827, filed on
Feb. 16, 2000, now abandoned.
(76) Inventors: William McCabe, Greenwood, SC
(US); David Wenstrup, Easley, SC Publication Classification
US
(US) (51) Int. Cl." .......................... B32B 27/04; B32B 27/12;
B29D 22/00; B65D 1/00
Correspondence Address: (52) U.S. Cl. ......................... 442/149; 442/181; 428/36.1
Jeffery E. Bacon
Legal Department, M-495 (57) ABSTRACT
PO Box 1926
Spartanburg, SC 29304 (US) A composite fabric for use as a replacement for Vinyl
transportation vehicle Seating trim is described. The com
posite includes a woven fabric bonded to a nonwoven
(21) Appl. No.: 10/368,302 Substrate, and is desirably Substantially all-polyester. The
composite has physical properties Superior to that of con
ventional Vinyl materials, yet is lighter weight. In addition,
(22) Filed: Feb. 18, 2003 the composite is readily and efficiently recyclable.
US 2003/0176127 A1 Sep. 18, 2003

COMPOSITE FOR USE IN THE MANUFACTURE measured according to Society of Automotive Engineers
OF TRANSPORTATION VEHICLE SEATING TRIM Test Method SAE J855 and fog of greater than about 70
0001. This application is a continuation of U.S. patent when tested according to FLTM BO 131-01. (As will be
application Ser. No. 09/504.827, filed on Feb. 16, 2000, readily appreciated by those of ordinary skill in the art, the
which is incorporated in its entirety herein by Specific term “fog” refers to the amount of matter which would
reference hereto. evaporate and build up on the interior of automobile glass as
given off by the interior car components.)
FIELD OF THE INVENTION 0008. In addition, the materials must have at least mini
0002 The invention generally relates to textile compos mal resistance to UV degradation, in order that they can
iteS particularly useful in the formation of trim for Seating in withstand extended periods of direct Sunlight. Furthermore,
transportation vehicles. More specifically, the invention if the fabrics are formed from a plurality of laminated layers,
relates to textile composites which are useful as a replace they generally must have a lamination bond strength of at
ment for the vinyl materials conventionally used in the least about 12 N when tested according to FLTMBN 151-05
manufacture of transportation vehicle Seating and the like. Method A. In addition, the performance characteristics of
the platform materials must be retained throughout a wide
BACKGROUND OF THE INVENTION range of temperatures and temperature changes, Since
vehicles can heat up rapidly in the Sun and become
0.003 Transportation vehicles such as cars, trucks, etc., extremely cold in response to frigid external temperatures.
typically have Seats which are covered with Some form of 0009. As noted above, developments have heretofore
durable material designed to withstand a variety of forces. typically been directed to perfecting the performance and
The seats commonly include a platform (the part that the appearance of Seat platforms of transportation vehicles,
user contacts when he sits on the Seat), the seat back (the part while little attention has been paid to the vehicle trim. This
which faces the passenger sitting behind the seat), the skirt is believed in part to be due to the ready availability, low
(the part which extends substantially vertically downward cost, and adequate performance typically associated with
from the platform), and the sides, which connect all of the commercially available vinyl trim materials.
Seat parts together. In most transportation vehicle Seats, the
primary emphasis is placed on the Selection of the material 0010. One alternative which the assignee of the instant
for the platform, as this is the aesthetic focus of the Seat invention has developed for use as a vinyl replacement
within the vehicle. material is a woven fabric material having a polyurethane
foam backing. As illustrated more fully in the examples
0004 Common materials for the platform of such vehicle below, the polyurethane-backed fabric had similar fog to
Seats include leather and cloth, Such as woven fabrics, knit Vinyl, greater breaking Strength, and good tear and Seam
fabrics and the like. In the case of cloth seats, the fabrics Strength.
used are typically Selected to be heavy and highly decora
tive. Such decoration can be achieved through the use of a DETAILED DESCRIPTION
plurality of colored yarns, printing or dyeing of the mate
rials, Specific fabric constructions, pile Surfaces, etc. Where 0011. In the following detailed description of the inven
woven fabrics are used to form the platform of the seat, they tion, Specific preferred embodiments of the invention are
have typically included a heavy material (e.g. on the order described to enable a full and complete understanding of the
of about 8.5 to 19.0 oz/sq yd) bonded to a polyurethane foam invention. It will be recognized that it is not intended to limit
material, or a nonwoven backing formed from a wool/ the invention to the particular preferred embodiment
polyester or polypropylene/linen blend. Such backings are described, and although Specific terms are employed in
typically Secured to the fabric layer by way of polyurethane describing the invention, Such terms are used in a descriptive
adhesives. Sense for the purpose of illustration and not for the purpose
of limitation.
0005 The remaining portions of the vehicle seats are
collectively referred to herein as the Seating trim. Such items 0012. The instant invention is directed to a fabric com
of vehicle Seating are typically made from Vinyl material, posite which can be used as a Substitute for conventional
even where natural leather has been used to form the Seat Vinyl trim materials. More Specifically, the invention
platform. describes a composite which provides Superior performance
0006 Some considerations that vehicle seating fabric capabilities as compared with conventional vinyl trim mate
manufacturers must take into account when designing the rials, while also providing an enhanced aesthetic appear
fabrics are the particular physical parameters which must be ance. Furthermore, the composite of the instant invention is
achieved. For example, automobile manufacturers typically readily and efficiently recyclable, without the need for
require that fabrics (materials) used for their seats have high Separation of the material inputs.
breaking and tear strength (typically on the order of about 0013 In addition, the material of the instant invention
270N-489 N in each of the warp and fill directions when achieves performance results Superior in nature to the con
measured according to ASTM D 5034 and ASTM D 1117, ventional vinyl trim materials, and at a lower weight. This is
respectively), and seam strengths of at least about 289N-310 of particular advantage in that transportation vehicle manu
N, when tested according to Ford Laboratory Test Method facturers are constantly trying to reduce the weight associ
(“FLTM) BN 119-01. ated with the interior of their vehicles in order to maximize
0007 Furthermore, it is typically desired for the materials fuel efficiency and load capacity.
to have stretch of at least about 4%x4% (warpxfill for flat 0014. The instant invention is directed to a composite
woven fabrics, and 5%x5% for woven velour fabrics) when having a fabric which is bonded to a nonwoven substrate. In
US 2003/0176127 A1 Sep. 18, 2003

a preferred form of the invention, the fabric is substantially size. However, thermoset and other types of nonwoven
all-polyester, as is the nonwoven Substrate. In a particularly materials could also be used within the Scope of the instant
preferred form of the invention, the fabric is bonded to the invention.
nonwoven Substrate by way of a polyester adhesive, pref 0021. The fabric layer is secured to the nonwoven Sub
erably of the low melt, low Viscosity (e.g., having a melting strate by way of an adhesive layer. In a preferred form of the
point of 115°-180° C. and a viscosity of 20,000-150,000 invention, the adhesive is a polyester adhesive, preferably of
c.p.) variety. the low melt, low Viscosity variety. For example, polyester
0.015 The overall fabric composite is desirably light adhesives having a melt point of about 140 C. have been
weight, preferably on the order of about 9.0 to about 20.0 found to perform well in the invention.
OZ/sq yd, and more preferably less than about 12 OZ/sq yd. 0022. The adhesive can be applied to the fabric or the
(AS will be readily appreciated, the overall weight will nonwoven Substrate in any conventional manner. For
depend on the weight of the backing used as well as that of example, it can be applied to one of the components by
the fabric and adhesive.) Of this overall weight, the fabric foaming, extruding, Screen printing, or the like. The adhe
desirably has a weight of about 4.5 oz/sq yd to about 8.0 Sive can be applied continuously acroSS the Surface of the
OZ/sq yd, and more preferably less than about 6 OZ/sqyd, and fabric and/or nonwoven Substrate or in a Spaced arrange
the nonwoven Substrate has a weight of about 3 OZ/sq yd to ment, Such as a Zebra-type configuration. In addition, the
about 12.0 OZ/sq yd, and more preferably about 4 OZ/sq yd. fabric could be backcoated, such as with an ethyl vinyl
The adhesives are desirably applied at a level of about 5-30 alcohol compound, to control the amount of Stretch in the
g/m, and more preferably at about 12-15 g/m. overall composite.
0016. The composite desirably has a fog of about 80 or
greater, even more preferably about 90 or greater, and even EXAMPLES
more preferably about 95 or greater. AS noted above, the fog
value is an indicator of the amount of matter which would 0023 Sample A-A conventional vinyl automotive seat
evaporate and build up on the glass components of the ing trim material was obtained. The material had a weight of
vehicle. The higher the fog number the lower the amount of 20 OZ/sq yd.
matter which would come off the material, with 100 being 0024. Sample B-A sample of the assignee's prior vinyl
the highest number possible (indicating no matter comes off trim replacement material was also obtained and tested. The
the material.) material had an overall composite weight of 10 OZ/sqyd, and
0.017. In addition, the breaking strength is significantly included a woven fabric having a weight of 5.2 oz/sq yd, a
greater than that of vinyl or the prior composite construction. backcoat of ethyl vinyl alcohol having a weight of 0.75 oz/sq
Furthermore the composite has higher elasticity, a Stronger yd, and a polyurethane foam backing material bonded to it.
lamination bond compared to that of the prior composite The polyurethane foam backing material had a weight of 4.8
construction, and a lighter weight than conventional vinyl OZ/sqyd, and was bonded to the backcoated fabric by a flame
materials. lamination process, Such processes being readily understood
by those having ordinary skill in the art.
0.018. As noted above, in a preferred form of the inven 0025 Sample C A composite material was produced
tion, the fabric, nonwoven Substrate, and adhesive Securing according to the instant invention. The composite material
the layers together are all formed from polyester. As will be
recognized by those of ordinary skill in the art, products had an overall weight of 9.5 oz/sq yd, and was formed from
which are 95% polyester can be classified as 100% recy a plain woven (59 endsx45 picks greige, 73 endsx50 picks
clable. However, additional processing is required during finished) all polyester fabric having a weight of 5.2 oZ/sq yd
the recycling operation to Separate the non-polyester com bonded to a nonwoven Substrate having a weight of 4.0 OZ/Sq
ponent of the material being recycled. Therefore, this pre yd. The fabric was bonded to the nonwoven Substrate using
ferred form of the invention enables the ready recyclability a hot melt, low Viscosity polyester adhesive applied accord
of the trim material without the added expense of the ing to conventional hot melt application methods at a rate of
additional non-polyester component removal operation. 12-15 g/m in a Zebra-type pattern.
0019. An additional feature required by most transporta 0026. Each of the materials were tested for fog, breaking
tion vehicle Seat covering materials is that they be flame Strength, tear Strength, Seam Strength, Stretch and lamination
bond as described below. The results are recorded in Table
retardant. To achieve this performance characteristic, manu A.
facturers typically include a flame retardant within the
polyurethane component of their Seating and trim materials. 0027 Fog: Fog was tested according to Ford Laboratory
However, the need for Such flame retardants can be elimi Test Method BO 131-01.
nated in the preferred embodiment of the composite of the
instant invention, due to the Self-extinguishing nature of the 0028 Breaking Strength: Breaking strength was tested
polyester used to form the components. according to ASTM D 5034.
0020. As noted above, the composite desirably includes a 0029 Tear Strength: Tear strength was tested according
layer of lightweight woven polyester fabric. The fabric is to ASTM D 1117.
preferably flat woven from textured polyester yarns. The 0030 Seam Strength: Seam strength was tested accord
composite also includes a nonwoven Substrate layer, which ing to Ford Laboratory Test Method BN 119-01.
is also preferably made from polyester. In a particularly
preferred form of the invention, the nonwoven material is a 0031 Stretch: Stretch was tested according to Society of
needled polyester fabric made from fibers 4-15 denier in Automotive Engineers test method J855.
US 2003/0176127 A1 Sep. 18, 2003

0.032 Lamination Bond: Lamination bond strength was 8. A composite according to claim 1, wherein Said adhe
tested according to Ford Laboratory Test Method BN 151-05 sive is provided at about 5-30 g/m.
Method A. 9. A composite according to claim 1, wherein Said woven
polyester fabric comprises a flat woven fabric having a
TABLE A weight of about 5 to about 5.5 oz/sq yd.
10. A composite according to claim 1, wherein Said
Fabric Test Sample A Sample B Sample C nonwoven Substrate has a weight of about 4 OZ/sq yd.
Fog 72.69 72.3 95.86 11. A composite according to claim 1, wherein Said
Breaking SO2N x 566 N 1328 NX 951 N. 1414 N x 1043 N composite has an overall weight of about 7 to about 12 OZ/sq
Strength yd.
Tear Strength 208 N x 83 N 2O6 N x 161 N 395 N x 346 N.
Seam Strength 497 Nx 653 N. 641 N x 765 N 649 NX 782 N 12. A composite according to claim 1, wherein Said
Stretch 21% x 37% 3% x 0% 13% x 21% adhesive is provided between said woven fabric layer and
Lamination Not tested 14.6 N x 15.2 N. 28.9 NX 26.6 N Said nonwoven Substrate in a plurality of discrete locations.
Bond 13. A composite according to claim 1, wherein Said
adhesive extends Substantially continuously between Said
woven fabric layer and Said nonwoven Substrate.
0033. As illustrated, the composite fabric of the instant 14. A composite according to claim 1, wherein Said
invention had Superior fog performance to that of the prior composite has a fog value of about 80 to about 100 when
trim materials, as well as Superior breaking Strength and tear tested according to SAE J1351.
Strength. Furthermore, the composites achieved the Superior 15. A composite according to claim 1, wherein Said
performance characteristics at a lower weight than with prior composite has a breaking Strength of about 1350 N or greater
constructions. As a further advantage, the composite of the in the warp direction, and a breaking strength of about 1000
instant invention can be readily and efficiently recycled, due N or greater in the fill direction when tested according to
to its Substantially all polyester construction. ASTM D 5O34.
0034. In the specification there has been set forth a 16. A composite according to claim 1, wherein Said
preferred embodiment of the invention, and although spe composite has a tear Strength of about 250 N or greater in the
cific terms are employed, they are used in a generic and warp direction, and about 175 or greater in the fill direction
descriptive Sense only and not for purpose of limitation, the when tested according to ASTM D 1117.
Scope of the invention being defined in the claims. 17. A composite according to claim 1, wherein Said
We claim:
composite has stretch of about 5% or greater in the warp
1. A composite for use in the manufacture of Seating trim direction and about 15% or greater in the fill direction when
in transportation vehicles comprising: tested according to SAE J855.
18. A composite according to claim 1, wherein Said
a woven polyester fabric having a weight of about 4.5 to composite has a lamination bond strength of about 20N or
about 8 OZ/sq yd; greater in each of the warp and fill directions.
a polyester nonwoven Substrate having a weight of about 19. An Seat covering for a transportation vehicle Seat
comprising:
3 to about 12 OZ/sq yd; and
an adhesive Securing Said fabric to Said nonwoven Sub a Seat platform formed from a first material, and
Strate, wherein Said composite has a fog of about 80 or Seat trim portions formed from a Second material opera
greater and a lamination bond of at least about 15 Nx15 tively associated with Said Seat platform, Said Second
N. material comprising a composite having a woven fabric
2. A composite according to claim 1, wherein Said com layer Secured to a nonwoven Substrate by way of an
posite is substantially 100% recyclable. adhesive layer, Said Second material having a weight
3. A composite according to claim 1, wherein Said non which is at least about 3 OZ/sq yd less than the weight
woven Substrate consists essentially of polyester fibers. of Said first material.
4. A composite according to claim 1, wherein Said adhe 20. A Seat covering according to claim 19, wherein Said
Sive comprises a low melt thermoplastic adhesive. woven fabric layer comprises a polyester fabric having a
5. A composite according to claim 1, wherein Said adhe weight of about 3 to about 6 OZ/sq yd, and Said nonwoven
Sive comprises a low melt polyester adhesive. Substrate comprises a nonwoven polyester fabric having a
6. A composite according to claim 1, wherein Said non weight of about 3 to about 5 oz/sq yd.
woven Substrate consists essentially of polyester fibers, and 21. A Seat covering according to claim 20, wherein Said
Said adhesive comprises a low melt polyester adhesive. adhesive layer comprises a layer of low melt polyester
7. A composite according to claim 1, wherein Said non adhesive, Such that Said Second material is Substantially
woven Substrate consists essentially of polyester fibers, and 100% recyclable.
Said adhesive is a low melt polyester adhesive, Such that Said
composite is Substantially all-polyester.