CARBON FIBER MIXED FABRIC VEHICLE HOOD AND VEHICLE SEAT COVER COMPRISING THE SAME

DESCRIPTION

Technical field

This invention relates to a fabric comprising carbon fibre, or carbon fibre fabric.

Background art Known in the prior art are fabrics comprising carbon fibre warp and weft yarns.

Aim of the invention

To meet the need for a fabric comprising carbon fibre and capable of elongation by at least 2-3% compared to prior art carbon fibre fabrics, when subjected to traction, the Applicant has developed a fabric comprising carbon fibre with an interlacement of carbon fibre yarns and polymer fibre yarns.

Advantageously, the polymer fibre yarns, woven with the carbon fibre yarns give the fabric the required elongation capability. Brief description of the drawings

Further features and advantages of this solution are more apparent in the exemplary, hence non-limiting description below, with reference to a preferred embodiment of a carbon fibre fabric as illustrated in the accompanying drawings, in which: - Figure 1 is a schematic view of a portion of carbon fibre fabric according to this description;

Figure 2 is a schematic cross sectional view of the fabric of Figure 1 ; Figure 3 is another schematic cross sectional view of the portion of Figure 1 ; - Figure 4 is a schematic cross sectional view of a portion of a vehicle hood made from the carbon fibre fabric according to this description;

Figure 5 is a schematic perspective view of a vehicle comprising the hood made from the carbon fibre fabric according to this description;

Figure 6 schematically illustrates the hood of Figure 5; Figure 7 is a scaled-up detail of a first variant embodiment of the hood of Figure 5;

Figure 8 is a scaled-up detail of a second variant embodiment of the hood of Figure 5; - Figure 9 is a scaled-up detail of a third variant embodiment of the hood of Figure 5;

Figure 10 is a scaled-up detail of a fourth variant embodiment of the hood of Figure 5;

Figure 11 is a variant of the hood of Figure 6; - Figure 12 is a schematic cross sectional view of a portion of a vehicle seat upholstery cover made from the carbon fibre fabric according to this description;

Figure 13 is a schematic perspective view of a vehicle seat comprising the upholstery cover made from the carbon fibre fabric according to this description;

Figure 14 is a scaled-up detail of a first variant embodiment of the seat of Figure 13;

Figure 15 is a scaled-up detail of a second variant embodiment of the seat of Figure 13; - Figure 16 is a scaled-up detail of a third variant embodiment of the seat of Figure 13;

Figure 17 is a scaled-up detail of a fourth variant embodiment of the seat of Figure 13.

Detailed description of preferred embodiments of the invention The reference numeral 1 denotes a fabric according to this description.

The fabric 1 comprises carbon fibre yarns 3 and polymer fibre yarns 4 woven to form an interlacement 2.

In other words, the fabric 1 has an interlacement 2 of carbon fibre yarns 3 and polymer fibre yarns 4. The carbon fibre yarns 3 have a linear density of between 50 and 5000 g/km, comprising from 1000 to 60000 filaments, specifically from 3000 to 24000 filaments between 5 and 10 microns in diameter.

More specifically, the interlacement 2 comprises a weft of carbon fibre yarns 3 and a warp of polymer fibre yarns 4.

Preferably, with reference to the carbon fibre yarn 3 of the interlacement 2, the number of filaments per yarn is between 1 K and 60K, inclusive, in particular, between 3K and 12K, inclusive.

In an alternative embodiment, the interlacement 2 comprises a weft of polymer fibre yarns 4 and a warp of carbon fibre yarns 3.

Advantageously, the polymer fibre yarns 4, woven with the carbon fibre yarns give the fabric 1 an elastic elongation capability at least along the predominant direction of extension of the yarns 4 themselves in the fabric 1.

When the polymer fibre yarns 4 constitute the warp of the fabric 1 , the fabric 1 is elastically elongatable along the warp.

When the polymer fibre yarns 4 constitute the weft of the fabric 1 , the fabric 1 is elastically elongatable along the weft.

The elongation of the fabric 1 is greater along the direction of the polymer fibre yarns 4 than the elongation of the fabric 1 along the direction of the carbon fibre yarns 3.

In an embodiment, the fabric 1 , if subjected to traction, is elongated by up to 5% and at least by 2% or 3%.

In an embodiment, the polymer fibre yarns 4 are polyester yarns. Alternatively, the polymer fibre yarns 4 are polypropylene yarns.

In yet another embodiment, the polymer fibre yarns 4 are aramid fibre yarns. The use of polymer fibre yarns 4 woven with the carbon fibre yarns 3 allows making a “hybrid” interlacement 2 which can respond to traction loads by alongation in particular along a direction of application of the load. Preferably, the interlacement 2 is a “twill” interlacement 2, specifically “twill 2/1 ”. Preferably, the interlacement 2 comprises a pair of warp yarns 4 of polymer fibre woven with a single yarn 3 of carbon fibre (see Figure 2).

As regards bending strength according to the Bally test, mechanical laboratory tests have shown that the fabric 1 according to this description is able to exceed more than 25,000 working cycles, compared to the 5,000 working cycles of prior art carbon fibre fabrics.

In a preferred embodiment, the fabric 1 comprises a protective layer 7 applied on the interlacement 2, specifically to make the fabric 1 water repellent.

More specifically, the protective layer 7 comprises a polymer-based solvent. The protective layer 7 confers a water impermeability of 2000 mm water column at 2 bar.

The protective layer 7 confers scratch resistance of at least 20,000 working cycles.

The protective layer 7 is disposed at least along one of the surfaces of extension of the interlacement 2, preferably a surface which, in conditions of use, is exposed towards the outside atmosphere.

With reference to its elongation properties, the fabric 1 may be used in numerous technical fields requiring the light weight and mechanical strength of the carbon fibre combined with the capability of elongation by traction. For example, an awning for nautical use, not illustrated, may comprise a fabric 1 according to this description.

In this context, with reference in particular to Figures 4 and 5, a hood 8 for a vehicle 100 having a predominant direction of extension D is illustrated. The hood or roof 8 is of a folding type and the vehicle 100 is a convertible with a folding roof that is movable between an open configuration, illustrated in Figure 5, where the interior of the vehicle 100 is covered, and a closed or folded configuration, where the interior of the vehicle 100 is uncovered.

The hood 8 comprises at least one rubber layer 9, preferably a layer 9 of butyl rubber, interposed between at least one first layer or inner layer 10, intended to face towards the inside of the vehicle 100, and a second layer or outer layer 11 , intended to face towards the outside of the vehicle 100. The outer layer 11 comprises the fabric 1 , preferably coated with the protective layer 7. The first layer 10 of the hood 8 is, for example, made of synthetic material, preferably acrylic material.

In order to test the elongation of the fabric 1 , a tensile test to DIN EN 13934- 1 was carried out.

The test pieces for the tensile test included a warp of carbon fibre yarns 3 and a weft of polymer fibre yarns 4, specifically polyester.

The graph below shows the result of the test.

Elongation %

The fabric 1 elongates by up to 5% and by at least 2% and 3%.

With reference to Figure 6, it may be observed that the hood 8 preferably and schematically comprises a main portion 13, intended to at least partly define a top or roof of the vehicle 100, and at least a first side portion 14 and a second side portion 15, each defining at least part of a respective flank of the vehicle 100.

The first and second side portions 14, 15 are disposed on opposite sides of the main portion 13 along the second direction D.

The first and second side portions 14, 15 each have a respective outer perimeter edge 23, 24, intended to come into contact with the body of the vehicle 100 when the hood 8 is in the closed condition. More specifically, the first side portion 14 and the main portion 13 are joined along respective inner perimeter edges 14a and 13a, preferably by seam stitches which, for example, allow better folding of the hood 8.

The second side portion 15 and the main portion 13 are joined along respective inner perimeter edges 15a and 13b, preferably by seam stitches. The main portion 13 has a first inner perimeter edge 13a and a second inner perimeter edge 13b.

In a first embodiment, illustrated in Figure 7, the inner perimeter edge 14a of the first side portion 14 and the first inner perimeter edge 13a of the main portion 13 are joined in such a way that one face of the inner perimeter edge 14a of the first side portion 14 abuts against one face of the first inner perimeter edge 13a of the main portion 13 to define a crest 16 extending along the length of the edges 13a, 14a.

This feature also applies to the inner perimeter edge 15a of the second side portion 15 and the second inner perimeter edge 13b of the main portion 13. In a second variant embodiment, a first seam 19 joins the face of the inner perimeter edge 14a of the first side portion 14 to the face of the first inner perimeter edge 13a of the main portion 13 (Figure 8).

This feature also applies to the inner perimeter edge 15a of the second side portion 15 and the second inner perimeter edge 13b of the main portion 13. The first seam 19 is transverse to the longitudinal direction of extension of the crest 16.

In a third, alternative variant embodiment (Figure 9), the crest 16 provided with the first seam 19 is folded onto part of the main portion 13 or onto part of one between the first side portion 14 and the second side portion 15. These variants optionally comprise a layer of adhesive material 20 placed at least on the crest 16 in order to hide it.

These variants also optionally comprise at least a second seam 21 joining a portion of the layer of adhesive material 20 to the main portion 13. The second seam 21 runs parallel to a respective inner edge 13a, 13b, the first inner perimeter edge 13a and the second inner perimeter edge 13b of the main portion 13.

A further option is a second seam 21 joining a respective portion of the layer of adhesive material 20 to the first side portion 14.

The second seam 21 runs parallel to a respective perimeter edge 14a of the first side portion 14.

A further option is a second seam 21 joining a respective portion of the layer of adhesive material 20 to the second side portion 15.

The second seam 21 runs parallel to a respective perimeter edge 15a of the second side portion 15.

In a fourth embodiment, illustrated in Figure 8, a flap 17 of the inner perimeter edge 14a of the first side portion 14 is connected, preferably by seams, to a flap 18 of the first inner perimeter edge 13a of the main portion 13 in such a way that the main portion 13 and the first side portion 14 overlap at least at the respective flaps 18, 17 which are placed on top of one another.

This feature also applies to the inner perimeter edge 15a of the second side portion 15 and the second inner perimeter edge 13b of the main portion 13. According to this description, the main portion 13 of the hood 8 comprises the fabric 1 , or at least the main portion 13 is preferably made from the fabric 1.

Advantageously, that way, the hood 8, at least at the main portion 13, has all the properties of the fabric 1 , including the elastic properties.

The first side portion 14 and the second side portion 15 each comprise a respective elasticized element 22.

Advantageously, each elasticized element 22 ensures a desired folding direction during the opening/closing of the first side portion 14 and second side portion 15 of the hood 8, thus preventing the main portion 13 from folding. In effect, it has been found that folding the main portion 13 when the hood 8 is opened or closed leads to the formation of creases where the structure of the fabric 1 eventually wears down.

With reference to the first side portion 14, the elasticized element 22 is disposed between the outer perimeter edge 23 and the inner perimeter edge 14a.

Preferably, the elasticized element 22 extends from the outer perimeter edge 23 to the inner perimeter edge 14a.

With reference to the second side portion 15, the elasticized element 22 is disposed between the outer perimeter edge 24 and the inner perimeter edge 15a.

Preferably, the elasticized element 22 extends from the outer perimeter edge 24 to the inner perimeter edge 15a.

The elasticized element 22 is inclined to the direction of extension of the outer perimeter edge 23 and to the direction of extension of the inner perimeter edge 14a of the first side portion 14.

The elasticized element 22 is inclined to the direction of extension of the outer perimeter edge 24 and to the direction of extension of the inner perimeter edge 15a of the second side portion 15.

The elasticized element 22 of the first side portion 14 and of the second side portion 15 are disposed relative to each other in such a way that their directions of extension are convergent.

These properties allow the hood 8 to pass from the closed or folded configuration to the open configuration since the open configuration usually requires the hood to be elongated to an extent not normally obtainable with fabrics comprising both warp and weft yarns made from carbon fibre.

Figure 12 shows a schematic cross sectional view of a detail of an upholstery cover 100 for rigid or semi-rigid elements.

The cover 100 comprises a layer of the fabric 1 applied on a layer of rubber 9, preferably butyl rubber.

The layer of rubber 9 has a thickness less than or equal to 0.5 mm. The layer of fabric 1 and the layer of rubber 9 have respective through holes. Figure 13 in particular illustrates a seat 200 for vehicles, specifically automobiles, at least partly comprising the cover 100.

The seat 200 comprises portions of the cover 100 stitched together as illustrated in Figures 14 to 17.

With reference to Figure 14, the seat 200 comprises a first inner perimeter edge 114a of a first portion 114 of the cover 100 and a second inner perimeter edge 113a of a second portion 113 of the cover 100 which are joined together in such a way as to form a crest 116 extending along the length of the inner perimeter edges 113a, 114a.

With reference to Figure 15, a first seam 119 joins the face of the inner perimeter edge 114a to the face of the second inner perimeter edge 113a. The crest 116 provided with the first seam 119 is folded onto part of the first portion 113 or onto part of the second portion 114. A layer of adhesive material 120 is placed at least on the crest 116 in order to hide it.

With reference to Figure 16, at least a second seam 121 joins a portion of the layer of adhesive material 120 to the first portion 113.

A second seam 121 joins a respective portion of the layer of adhesive material 20 to the second portion 114.

With reference to Figure 17, a flap 117 of the inner perimeter edge 114a of the first portion 114 is connected, preferably by seams, to a flap 118 of the first inner perimeter edge 113a of the second portion 113 in such a way that the first portion 113 and the second portion 114 overlap at least at the respective flaps 117, 118.