3D Fiber Cushion Material With Local Hardness Control
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Solution Overview
Problem
The production of vehicle seat cushions with varying hardness levels is costly and inefficient, as it requires separate production and installation of cushion elements with specific hardness properties.
Innovation Solution
A method involving the extrusion of thermoplastic polymer fibers to form a 3D tangle of irregularly distributed endless fibers, which are then solidified to create a cushion material with varying density and hardness properties, achieved through temporal and local variations in extrusion pressure and conveyance speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cushion elements with different hardness are produced and installed, then local varying support properties are achieved, but production expense increases
Solution Approach 1:
The patent merges multiple cushion elements with different hardness properties into a single integrated cushion component. The extrusion device produces a continuous curtain of molten fibers that are formed into a three-dimensional tangle with spatially varying density, eliminating the need to separately produce and assemble multiple cushion elements with different hardness levels.
Solution Approach 2:
The patent applies local quality by creating regions with different fiber density and hardness within a single cushion component. The extrusion process varies the fiber distribution and packing density at different locations, allowing soft regions and hard regions to coexist in one piece, thereby providing locally varying support properties without increasing production complexity.
2Adaptability or versatility
If multiple cushion elements are separately produced and installed, then varying hardness is achieved, but production time and complexity increase
Solution Approach 1:
The invention combines the production of multiple cushion elements into a single extrusion process. The extrusion device with multiple extrusion nozzles produces a curtain of molten fibers that are simultaneously formed into a integrated structure with varying density, reducing the number of production steps and assembly operations required.
Solution Approach 2:
The patent employs dynamic control of the extrusion process to vary fiber density and hardness during production. The conveyance speed of the curtain through the rollers is adjusted to control the degree of fiber entanglement and fusion, allowing real-time variation of material properties within the continuous production process.
3Strength
If fiber density is increased to improve support, then hardness increases, but air circulation and moisture absorption decrease
Solution Approach 1:
The patent applies local quality by creating spatially varying fiber density within the cushion material. Regions with higher fiber density provide enhanced support properties, while regions with lower density maintain air circulation and moisture absorption capabilities. This localized variation allows the cushion to simultaneously deliver both firm support and breathability in different areas.
Solution Approach 2:
The patent utilizes the porous structure of the three-dimensional fiber tangle to maintain air circulation and moisture absorption. The entangled and fused fibers create interconnected voids and channels that allow air flow and moisture transport, even in regions with higher density. The porous architecture is preserved through the extrusion and forming process, balancing support and breathability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the direct formation of cushion materials with regions of varying density and hardness, reducing production costs and enabling efficient production of seat cushions with tailored comfort and support properties.
Implementation Method 1
a curtain of molten endless fibres falling due to gravity
Implementation Method 2
endless fibers which are looped together and fused together
Implementation Method 3
Solidifying the 3D tangle by immersion in a cooling liquid
Data Source
AI summary
A Method for producing a cushion material for manufacture of seat cushions may extrude a material comprising at least one thermoplastic polymer in an extrusion device, thereby producing a curtain of molten endless fibers, that falls due to gravity. The extrusion device comprising multiple extrusion nozzles that are distributed in a longitudinal direction and in a lateral direction of the extrusion device, and a pressure adjustment arrangement to adjust an extrusion pressure. The Method may receive the curtain of molten endless fibers between two counter-rotating rollers, thereby producing a 3D tangle of irregularly distributed endless fibers which form loops that are fused together. The Method may solidify the 3D tangle by immersion in a cooling liquid.