Air permeable fabric

Abstract

A nonwoven permeable structure fabric for use in the construction of automotive seats. The permeable structure fabric includes 60%-99% by weight of a first fiber and the first fiber has a first mass and a first melting point. The permeable structure includes 1-40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point. The first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension. The first mass is between about 10 denier and about 30 denier.

What is claimed is: 
     
         1 . A nonwoven permeable structure fabric for use in the construction of automotive seats, the permeable structure fabric comprising:
 60%-99% by weight of a first fiber and the first fiber has a first mass and a first melting point;   1-40% by weight of a second fiber and the second fiber has a second melting point that is lower than the first melting point;   the first fiber and the second fiber are mechanically entangled in a first dimension and the first fiber and second fiber are mechanically entangled in a second dimension that is generally perpendicular to the first dimension; and   wherein the first mass is between about 10 denier and about 30 denier.   
     
     
         2 . The nonwoven permeable structure fabric according to  claim 1 , wherein the fibers are entangled by mechanical punching. 
     
     
         3 . The nonwoven permeable structure fabric according to  claim 1 , wherein the weight of the permeable structure fabric is 400 gsm. 
     
     
         4 . The nonwoven permeable structure fabric according to  claim 1 , wherein the denier of the first fiber is between about 12 and 25. 
     
     
         5 . The nonwoven permeable structure fabric according to  claim 4 , wherein the denier of the first fiber is about 16. 
     
     
         6 . The nonwoven permeable structure fabric according to  claim 4 , wherein the denier of the first fiber is about 20. 
     
     
         7 . The nonwoven permeable structure fabric according to either of  claims 5 and 6 , wherein the weight of the permeable structure fabric is between 250 gsm and 450 gsm. 
     
     
         8 . The nonwoven permeable structure fabric according to either of  claims 5 and 6 , wherein the thickness of the permeable structure fabric is between about 5.0 mm and about 7.5 mm. 
     
     
         9 . The nonwoven permeable structure fabric according to any of  claims 1 through 8 , wherein the first fiber is recycled polyester. 
     
     
         10 . The nonwoven permeable structure fabric according to  claim 9  wherein the first fiber comprises about 85% of the nonwoven permeable structure. 
     
     
         11 . The nonwoven permeable structure fabric according to either of  claims 9 and 10 , wherein the second fiber is a lower melt polyester having a denier of about 4. 
     
     
         12 . The nonwoven permeable structure fabric according to either of  claims 9 and 10 , wherein the second fiber is a lower melt polyester having a denier of about 10. 
     
     
         13 . The nonwoven permeable structure fabric according to either of  claims 9 and 10 , wherein the second fiber is Polylactic acid Fiber. 
     
     
         14 . The nonwoven permeable structure fabric according to either of  claims 9 and 10 , wherein the second fiber is a low melt bicomponent Copolyester/Polyester Sheath/Core fiber. 
     
     
         15 . The nonwoven permeable structure fabric according to either of  claims 9 and 10 , wherein the second fiber is a low melt bicomponent Copolyester/Polyester Sheath/Core fiber having a denier of about 10. 
     
     
         16 . The nonwoven permeable structure fabric according to  claims 9 and 10 , wherein the airflow is between about 0.179 m 3 /s and about 0-0.297 m 3 /s. 
     
     
         17 . The nonwoven permeable structure fabric according to  claims 9 and 10 , wherein the nonwoven permeable structure fabric is laminated to a face fabric with an adhesive layer sandwiched therebetween.