This invention relates to composite foam backed fabrics, particularly to such fabrics which are suitable for use in automobiles and most particularly to fabrics wherein the foam is protected by a scrim layer applied to the face remote from the fabric face.
Automotive fabrics are usually knitted or woven and may have a pattern to fit the general design and decor of the automobile. Normally the fabric is mounted on a foam backing and the resulting composite is further mounted on a scrim which can improve the dimensional stability of the composite and which, more importantly protects the otherwise exposed surface of the foam and allows the fabric to be more easily handled when it is being cut and sewn to fit around the shape of a seat and the like.
Traditionally woven or knitted scrims have been used for such applications. They suffer from the disadvantages that any defect in the scrim results in that portion of the composite having to be rejected which increases the manufacturing cost. It is known to apply a flame retardant to knitted scrims.
According to the present invention there is provided a composite layered fabric structure comprising a surface layer of knitted or woven face fabric, an intermediate foam layer attached to the surface layer, and a scrim layer attached to the foam surface remote from the face fabric, wherein the scrim comprises a non-woven and the composite is able to be resiliently stretched more than 5%, preferably more than 6 to 15%, particularly preferably more than 7% to 10% in both longitudinal and transverse directions under a load of 10 kg. When stretched accordingly, the scrim does not tear. Composites showing this stretching ability can generally be stretched by hand more than 5% in both longitudinal and transverse directions.
The knitted or woven fabric is preferably a polyester fabric, most preferably a polyester jacquard. Its preferred weight is in the range of 150 to 300 g/m2. The fabric should be able to be resiliently stretched more than 5% in both longitudinal and transverse directions under a load of 10 kg.
The foam layer is preferably composed of polyester. Its preferred thickness is in the range 2 mm to 7 mm. The foam layer has an elasticity and stretching ability which is significantly larger than that of the fabric and the scrim layer.
The scrim preferably consists of a non-woven, most preferably a polyester non-woven. Other usable scrims include nylon scrims. The elasticity of the scrim is generally larger than that of the fabric, preferably by at least 10%. Preferred scrims have a stretching ability of more than 10% in lengthwise direction, more preferred are those having a stretching ability of more than 15% to 35% in lengthwise direction. The weight may be in the range 25 gm−2 to 70 gm−2, preferably about 30 gm−2. By about 30 g it is intended to indicate a range of 27-33 g. The use of a low weight scrim such as about 30 gm−2 may aid the overall elasticity of the composite. The scrim does not tear when the composite of the present invention is stretched 5%, preferably 10%, more preferably up to 15%.
The scrim is desirably made from polyester that is flame retardant sufficiently for the composite to pass ISO3795 FMVSS302. Advantageously the scrim has a burn rate of less than 80 mm measured by that test.
The composite layer fabric structure is preferably produced by flame-laminating the three layers.
A particular advantage of this invention is the ability to manufacture self-extinguishing thin composite laminates. A further advantage of incorporating flame retarding properties into the scrim is that it is more cost effective way to achieve the required performance than the application of a flame retardant by other means, for example by applying it to the face fabric.
The invention will now be further described by way of example only and with reference to
Different fabrics were flame-laminated to a layer of polyester foam of 3 mm thickness which in turn was flame-laminated to a polyester non-woven scrim of 30 g per m2 weight which has been fabricated to make it flame retardant. The elongation (stretch) of the composite was determined as follows:
The test method defines a procedure for determining elongation under constant load conditions. Two grips capable of accommodating the width of the test specimen. One grip shall be capable of being attached to a rigid support so that when the test specimen is inserted centrally, it hangs in a vertical plane. The other grip shall be constructed so that dead loads may be added to bring it to the required total weight (e.g. 10 kg). The test comprises the following steps:
The following results were obtained:
Number | Date | Country | Kind |
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0124507.5 | Oct 2001 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP02/11430 | 10/11/2002 | WO |