This invention relates to a laminated fabric article for use in a vehicle component material, to a vehicle component material, to a vehicle component, to a vehicle, and to methods of manufacturing thereof.

Volatile organic compounds (VOC) are a group of carbon-based chemicals with high vapour pressures at room temperature which cause them to readily vaporise into the air under certain conditions. VOCs are commonly present in the chemical composition of materials making up the interior trim of vehicles. Although levels of VOC emissions resulting from off-gassing of the vehicle interior materials may decrease as a vehicle gets older, elevated vehicle temperatures may result in the VOC emissions reverting to higher levels. Prolonged exposure to VOC emissions could lead to adverse health conditions such as skin irritation, headaches and fatigue, and also could potentially result in more serious diseases such as asthma and cancer.

According to a first aspect of the invention, there is provided a laminated fabric article for use in a vehicle component material, the laminated fabric article comprising first and second layers, the first layer in the form of a face fabric structure, the second layer in the form of a three-dimensional weft knitted fabric structure, wherein the three-dimensional weft knitted fabric structure includes first and second knitted substrates separated by an intermediate textile spacer layer.

Conventional foam-based material used in vehicle interior trim includes an open cell polyurethane foam layer laminated between a fabric layer and a scrim layer. The structure and composition of the conventional foam-based material and its method of manufacture provide sources of high levels of VOC emissions. Firstly, due to its chemical structure, off gassing of the polyurethane foam layer provides a source of relatively high VOC emissions. In addition, during manufacture of the conventional foam-based material, vaporised VOCs may become trapped within the open cell structure of the polyurethane foam layer, and the trapped VOCs may leak out over time, thus providing another source of VOC emissions. Moreover, the VOC emissions of the conventional foam-based material is further increased by the use of a flame lamination process to bond the polyurethane foam layer to the fabric and scrim layers by directly exposing the surfaces of the polyurethane foam layer to a flame in order to melt the exposed surfaces before bringing the molten surfaces into contact with the fabric and scrim layers. The inventors have found that the combination of the face fabric structure and the three- dimensional weft knitted fabric structure in the laminated fabric article of the invention results in a composite material which can be used as a vehicle component material with improved properties when compared to the conventional foam-based material.

The weft knit construction of the three-dimensional weft knitted fabric structure provides the laminated fabric article with multi-axial stretch properties which in turn provides the laminated fabric article with the flexibility to conform to a wide range of shapes of different vehicle components, thereby enabling the laminated fabric article to be readily moulded and formed around the vehicle components. Also, the weft knit construction of the three- dimensional weft knitted fabric structure advantageously enables the laminated fabric article to maintain its form and shape for a longer time than the conventional foam-based material, since the polyurethane foam layer degrades over time due to exposure to heat and pressure.

In addition, the use of the intermediate textile spacer layer to separate the first and second knitted substrates in the three-dimensional weft knitted fabric structure enables the laminated fabric article of the invention to not only have a similar thickness as the conventional foam-based material but also provide a cushioning effect like the conventional foam-based material.

The inclusion of the three-dimensional weft knitted fabric structure in the laminated fabric article of the invention therefore eliminates the need for the polyurethane foam layer, which has the beneficial effect of reducing VOC emissions since the three-dimensional weft knitted fabric structure can be knitted from one or more textile materials with negligible to zero VOCs present. The elimination of the polyurethane foam layer also removes the need to use the flame lamination process, which as mentioned above is another source of VOC emission, but instead permits the use of other lamination processes which result in lower VOC emissions.

Similarly, the face fabric structure can be constructed from one or more textile materials with negligible to zero VOCs present in order to further reduce VOC emissions.

Furthermore, the knitted surfaces of the first and second knitted substrates enables the three-dimensional weft knitted fabric structure to perform the same function as the scrim layer, thus eliminating the need for the scrim layer. This allows the laminated fabric article of the invention to have a reduced thickness and a reduced number of layers when compared to the conventional foam-based material.

T extile parameters of the face fabric structure and the three-dimensional weft knitted fabric structure, such as textile material, yarn composition, yarn count, yarn density and knitting parameters, may be selected to vary the properties of the laminated fabric article of the invention.

In embodiments of the invention, the face fabric structure may be provided as a warp knitted fabric structure, a non-woven fabric structure, a woven fabric structure, or a weft knitted fabric structure.

The face fabric structure may include, but is not limited to, a first elastomeric material. Preferably the first elastomeric material includes nylon. More preferably the first elastomeric material includes nylon filament yarns. It will be appreciated that the amount of nylon filament yarns may vary depending on the required stretch properties of the three- dimensional weft knitted fabric structure. For example, nylon filament yarns may be provided in the first elastomeric material so that the face fabric structure is composed of 100% nylon filament yarns, preferably with a brushed surface.

Constructing the face fabric structure from the first elastomeric material provides a reliable means of providing the laminated fabric article with stretch properties compatible for use in vehicle component materials.

In further embodiments of the invention, the three-dimensional weft knitted fabric structure may have a double knitted jersey configuration. This is one way of obtaining a fabric structure with the first and second knitted substrates separated by an intermediate textile spacer layer.

The three-dimensional weft knitted fabric structure may include, but is not limited to, a second elastomeric material. Preferably the second elastomeric material includes polyester, polyurethane and/or elastane. More preferably the second elastomeric material includes polyester filament yarns, polyurethane filament yarns and elastane filament yarns. It will be appreciated that the respective amounts of polyester, polyurethane and/or elastane filament yarns may vary depending on the required stretch properties of the three- dimensional weft knitted fabric structure. For example, polyester and polyurethane filament yarns may be provided in the second elastomeric material so that the three- dimensional weft knitted fabric structure is composed of 95% polyester filament yarns and 5% polyurethane filament yarns.

Constructing the three-dimensional weft knitted fabric structure from the second elastomeric material provides a reliable means of providing the laminated fabric article with stretch properties compatible for use in vehicle component materials.

The intermediate textile spacer layer may be or may include a pile layer. The pile layer not only helps to provide separation between the first and second layers but also contributes to the elasticity of the three-dimensional weft knitted fabric structure. The yarns used in the pile layer may be selected to enhance the durability and shape retention of the laminated fabric article of the invention.

In still further embodiments of the invention, the laminated fabric article may further include an adhesive layer arranged between the first and second layers. This provides a reliable means of laminating the first and second layers together, which can be optimised to minimise or eliminate VOC emission.

The adhesive layer may include a water-based adhesive, and/or the adhesive layer may include a hot melt adhesive. The hot melt adhesive may be a thermoplastic adhesive, such as a co-polyamide adhesive. This removes the need for adhesives based on organic solvents, which are a source of VOCs.

As mentioned above, the face fabric structure and the three-dimensional weft knitted fabric structure can be knitted from textile materials with negligible to zero VOCs present in order to reduce VOC emission levels.

Materials of the face fabric structure and the three-dimensional weft knitted fabric structure may be selected to provide the laminated fabric article with a volatile organic compound emission level of less than 1 pg/m ² per hour for toluene, benzene, ethylbenzene, xylene, BTEX or styrene.

Materials of the face fabric structure and the three-dimensional weft knitted fabric structure may be selected to provide the laminated fabric article with a volatile organic compound emission level of less than 5 pg/m ² per hour for halogenated hydrocarbons. According to a second aspect of the invention, there is provided a vehicle component material comprising the laminated fabric article according to the first aspect of the invention or any one of its embodiments described hereinabove.

According to a third aspect of the invention, there is provided a vehicle component comprising the vehicle component material according to the second aspect of the invention.

The vehicle component may be a decorative vehicle component and/or a functional vehicle component. The vehicle component may be a vehicle interior component. For example, the vehicle component may be a vehicle interior trim component, such as carpeting and upholstery.

For the purposes of this patent specification, a decorative vehicle component is a vehicle component which is designed to alter the aesthetic appearance of the vehicle, a functional vehicle component is a vehicle component which is designed to enable or aid the driving function of the vehicle, and a vehicle interior component is a vehicle component which is located in the interior of the vehicle.

According to a fourth aspect of the invention, there is provided a vehicle comprising a vehicle component according to the third aspect of the invention or any one of its embodiments described hereinabove.

The advantages of the laminated fabric article of the first aspect of the invention and its embodiments apply mutatis mutandis to the vehicle component material, the vehicle component and the vehicle of the second, third and fourth aspects of the invention and their embodiments.

According to a fifth aspect of the invention, there is provided a method of manufacturing a laminated fabric article for use in a vehicle component material, the method comprising the steps of:

providing a face fabric structure;

providing a three-dimensional weft knitted fabric structure, wherein the three- dimensional weft knitted fabric structure includes first and second knitted substrates separated by an intermediate textile spacer layer; and

combining the face fabric structure and the three-dimensional weft knitted fabric structure to form first and second layers of the laminated fabric article. The advantages of the laminated fabric article of the first aspect of the invention and its embodiments apply mutatis mutandis to the method of the fifth aspect of the invention and its embodiments.

The method of manufacturing a laminated fabric article may include the step of providing the face fabric structure as a warp knitted fabric structure, a non-woven fabric structure, a woven fabric structure, or a weft knitted fabric structure.

The method of manufacturing a laminated fabric article may include the step of providing a first elastomeric material in the face fabric structure. Preferably the method of manufacturing a laminated fabric article includes the step of providing nylon in the first elastomeric material. More preferably the method of manufacturing a laminated fabric article includes the step of providing nylon filament yarns in the first elastomeric material.

The method of manufacturing a laminated fabric article may include the step of providing the three-dimensional weft knitted fabric structure with a double knitted jersey configuration.

The method of manufacturing a laminated fabric article may include the step of providing a second elastomeric material in the three-dimensional weft knitted fabric structure. Preferably the method of manufacturing a laminated fabric article includes the step of providing polyester, polyurethane and/or elastane in the second elastomeric material. More preferably the method of manufacturing a laminated fabric article includes the step of providing polyester filament yarns, polyurethane filament yarns and/or elastane filament yarns in the second elastomeric material.

The method of manufacturing a laminated fabric article may include the step of providing a pile layer as or in the intermediate textile spacer layer.

In embodiments of the method of manufacturing a laminated fabric article, the step of combining the face fabric structure and the three-dimensional weft knitted fabric structure to form the first and second layers of the laminated fabric article may further include the sub-step of arranging an adhesive layer between the first and second layers. In such embodiments, the adhesive layer may include a water-based adhesive, and/or the adhesive layer may include a hot melt adhesive. The hot melt adhesive may be a thermoplastic adhesive, such as a co-polyamide adhesive. The combination of the face fabric structure and the three-dimensional weft knitted fabric structure can be carried out in many ways to form the first and second layers of the laminated fabric article.

For example, in further embodiments of the method of manufacturing a laminated fabric article, the step of combining the face fabric structure and the three-dimensional weft knitted fabric structure to form the first and second layers of the laminated fabric article may further include the sub-step of using a rolling process to combine the face fabric structure and the three-dimensional weft knitted fabric structure.

The rolling process is compatible with the step of arranging the adhesive layer between the first and second layers. More particularly, the step of combining the face fabric structure and the three-dimensional weft knitted fabric structure to form the first and second layers of the laminated fabric article may further include the sub-steps of heating the first, second and adhesive layers prior to the rolling process, and cooling the laminated fabric article subsequent to the rolling process.

The method of manufacturing a laminated fabric article may include the step of selecting materials of the face fabric structure and the three-dimensional weft knitted fabric structure to provide the laminated fabric article with a volatile organic compound emission level of less than 1 pg/m ² per hour for toluene, benzene, ethylbenzene, xylene, BTEX or styrene.

The method of manufacturing a laminated fabric article may include the step of selecting materials of the face fabric structure and the three-dimensional weft knitted fabric structure to provide the laminated fabric article with a volatile organic compound emission level of less than 5 pg/m ² per hour for halogenated hydrocarbons.

According to a sixth aspect of the invention, there is provided a method of manufacturing a vehicle component material comprising the steps of carrying out the method of manufacturing a laminated fabric article according to the fifth aspect of the invention or any one of its embodiments described hereinabove, and using the laminated fabric article to manufacture the vehicle component material.

The advantages of the vehicle component material of the second aspect of the invention apply mutatis mutandis to the method of the sixth aspect of the invention. According to a seventh aspect of the invention, there is provided a method of manufacturing a vehicle component comprising the steps of carrying out the method of manufacturing a vehicle component material according to the sixth aspect of the invention, and using the vehicle component material to manufacture the vehicle component.

The advantages of the vehicle component of the third aspect of the invention and its embodiments apply mutatis mutandis to the method of the seventh aspect of the invention and its embodiments.

The method of manufacturing a vehicle component may include the step of manufacturing the vehicle component as a decorative vehicle component and/or a functional vehicle component. The method of manufacturing a vehicle component may include the step of manufacturing the vehicle component as a vehicle interior component.

According to an eighth aspect of the invention, there is provided a method of manufacturing a vehicle comprising the steps of carrying out the method of manufacturing a vehicle component according to the seventh aspect of the invention or any one of its embodiments described hereinabove, and using the vehicle component to manufacture the vehicle.

It will be appreciated that at least one embodiment of a given aspect of the invention may also be used in combination with at least one embodiment of the other aspects of the invention.

It will be appreciated that the use of the terms“first” and“second”, and the like, in this patent specification is merely intended to help distinguish between similar features (e.g. the first and second layers, the first and second elastomeric materials), and is not intended to indicate the relative importance of one feature over another feature, unless otherwise specified.

A preferred embodiment of the invention will now be described, by way of a non-limiting example, with reference to the accompanying drawings in which:

Figures 1a and 1 b show schematically a laminated fabric article according to an embodiment of the invention;

Figure 2 shows schematically a knit construction of a three-dimensional weft knitted fabric structure of the laminated fabric article of Figure 1 ; Figure 3 shows schematically the use of the laminated fabric article of Figure 1 in as a material in a vehicle component; and

Figure 4 shows schematically a process for manufacturing the laminated fabric article of Figure 1.

The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic form in the interests of clarity and conciseness.

A laminated fabric article according to an embodiment of the invention is shown in Figures 1a and 1 b, and is designated generally by the reference numeral 10. The laminated fabric article 10 is for use in a vehicle component material.

The laminated fabric article 10 comprises first and second layers 12, 14, with an adhesive layer 16 arranged between the first and second layers 12, 14.

The first layer 12 is in the form of a face fabric structure, which is provided as a warp knitted fabric structure. The face fabric structure 12 is made of a first elastomeric material in the form of 100% nylon 6 filament yarns with a brushed surface, as shown in Figure 1a, which the inventors have assigned a product code“L801”. The face fabric structure 12 serves the purpose of achieving a certain aesthetic while having properties suitable for coping with physical and environmental conditions experienced in a vehicle interior. The face fabric structure 12 could be used for headlining or other decorative applications within the vehicle interior. It is envisaged that, in other embodiments of the invention, the face fabric structure 12 may instead be provided as a non-woven, woven or weft knitted fabric structure.

The second layer 14 is in the form of a three-dimensional weft knitted fabric structure with a double knitted jersey configuration, as shown in Figure 2, which can be manufactured using a double needle bar knitting machine. The double knitted jersey configuration provides the three-dimensional weft knitted fabric structure 14 with first and second knitted substrates 18,20 separated by an intermediate pile layer 22. The knitted substrates 18,20 and pile layer 22 of the three-dimensional weft knitted fabric structure 14 are made of a second elastomeric material which is composed of 95% polyester filament yarns and 5% polyurethane filament yarns. This results in a small amount of elastane in the knit construction which provides the three-dimensional weft knitted fabric structure 14 with desirable stretch properties. The presence of the pile layer 22 contributes to the elasticity and cushioning effect of the three-dimensional weft knitted fabric structure 14. The inclusion of the polyester and polyurethane filament yarns in the pile layer 22 help to enhance the durability and shape retention of the laminated fabric article 10. In the embodiment shown, the pile layer 22 has a thickness of 2 mm, but it will be appreciated that the thickness of the pile layer 22 may vary depending on the required overall thickness of the laminated fabric article 10.

In the embodiment shown, the adhesive layer 16 includes a hot melt adhesive in the form of a co-polyamide adhesive with low amounts of VOCs and low viscosity. It is envisaged that, in other embodiments of the invention, the co-polyamide adhesive may be replaced by another type of hot melt adhesive or by a water-based adhesive.

As a result of the weft knit construction of the three-dimensional weft knitted fabric structure 14, the laminated fabric article 10 is provided with multi-axial stretch properties which allows it to be readily used as a car component material for a car component, a non-limiting example of which is a car seat as shown in Figure 3. For example, the laminated fabric article 10 may be used as anti-squeak fabric for leather seats, bolster armrest linings, and map pockets. As mentioned above, the weft knit construction also enables the laminated fabric article 10 to maintain its form and shape for a longer time than the conventional foam-based material.

An exemplary method of manufacturing the laminated fabric article 10 of Figure 1 is shown in Figure 4.

Initially the hot melt adhesive 16 is applied onto the surface of one of the knitted substrates 18,20 of the three-dimensional weft knitted fabric structure 14, followed by the face fabric structure 12 being laid on top of the hot melt adhesive 16. The arrangement of the face fabric structure 12, hot melt adhesive 16 and three-dimensional weft knitted fabric structure 14 is then carried by a conveyor belt 24 through a heating zone 26 with upper and lower heating elements 26a, 26b to pre-heat the materials 12, 14, 16 before fed through a nip roller 28. The nip roller 28 applies pressure to the face fabric structure 12, hot melt adhesive 16 and three-dimensional weft knitted fabric structure 14 to form the laminated fabric article 10. Once the laminated fabric article 10 exits the nip roller 28, it is carried by another conveyor belt 30 through a cooling zone 32 to cool down the laminated fabric article 10. An example of a suitable machine for carrying out the above method of manufacture is the Reliant™ Powerbond Mark II laminator.

When tested as a vehicle interior trim component material, the laminated fabric article 10 was found to exhibit trace amounts of VOC emissions. More particularly, the laminated fabric article 10 exhibited a VOC emission level of less than 1 pg/m ² per hour for each of toluene, benzene, ethylbenzene, xylene, BTEX and styrene, and less than 5 pg/m ² per hour for halogenated hydrocarbons. These VOC emission levels are significantly below the VOC emission levels typically associated with conventional foam-based materials.

The negligible VOC emissions exhibited by the laminated fabric article 10, when compared to conventional foam-based materials, was a result of:

• the construction of the laminated fabric article 10 based on the three-dimensional weft knitted fabric structure 14 instead of the polyurethane foam layer used in conventional foam-based materials;

• the use of a rolling process, instead of a flame lamination process, in the manufacture of the laminated fabric article 10; and

• the use of an adhesive layer 16 which does not require organic solvents.

As mentioned above, a further benefit of the laminated fabric article 10 is the elimination of the scrim layer used in conventional foam-based materials, since the knitted surfaces of the first and second knitted substrates 18,20 enables the three-dimensional weft knitted fabric structure 14 to perform the same function as the scrim layer, thus allowing the laminated fabric article 10 of the invention to have a reduced thickness and a reduced number of layers when compared to the conventional foam-based material.

The combination of the face fabric structure 12 and the three-dimensional weft knitted fabric structure 14 in the laminated fabric article 10 of the invention therefore results in a laminated fabric article 10 which can be used as a vehicle component material with improved properties when compared to the conventional foam-based material.

It will be appreciated that the laminated fabric article 10 of the invention is applicable to a wide range of different vehicle components, including decorative and functional vehicle components, and particularly vehicle interior components. It will also be appreciated that the laminated fabric article 10 of the invention is applicable to a wide range of different vehicles.