3D Knitted Fabric Lamination With Integrated Heat-Setting

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Solution Overview

Problem

Current methods for heat-setting and laminating 3D knitted fabrics in motor vehicle interior construction require separate energy-intensive processes, leading to inefficient energy use and increased logistics costs.

Innovation Solution

A method and apparatus for simultaneously heat-setting and laminating 3D knitted fabrics on a carrier device using a laminating apparatus equipped with force-exerting, temperature control, impregnating, addition, and radiating devices, allowing for efficient energy utilization and reduced handling costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate heat-setting and lamination processes are used, then the 3D knitted fabric can be properly heat-set and laminated, but energy consumption increases and logistics costs rise

Engineering Contradiction:

Improveheat-setting qualityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent combines the heat-setting process and lamination process into a single integrated operation. The lamination device applies heat and pressure simultaneously to both heat-set the 3D knitted fabric and activate the adhesive yarn, eliminating the need for a separate autoclave heat-setting step. This merging of processes directly reduces energy consumption while maintaining the reliability of heat-setting quality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lamination device is designed to perform multiple functions: it acts as both a lamination device (activating adhesive yarn to bond fabric to carrier) and a heat-setting device (shaping the 3D knitted fabric through controlled heating). This multi-functionality allows a single device to accomplish what previously required two separate devices, thereby reducing overall energy consumption and process complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate heat-setting and lamination processes are used, then proper thermal treatment is achieved, but logistics costs and handling requirements increase

Engineering Contradiction:

Improvethermal treatment qualityVSAvoidlogistics cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging the heat-setting and lamination operations into a single simultaneous process, the patent eliminates the intermediate handling step where the fabric would need to be transferred from a heat-setting autoclave to a lamination device. This integration simplifies logistics, reduces handling requirements, and lowers manufacturing costs while maintaining thermal treatment quality.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If hot-melt adhesive yarn is used for lamination, then the fabric can be bonded to the carrier device, but additional energy input is required for adhesive activation

Engineering Contradiction:

Improvebonding strengthVSAvoidenergy input for adhesive activation

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent merges the heat input for heat-setting with the heat input for adhesive activation into a single thermal process. The lamination device applies heat that simultaneously heat-sets the 3D knitted fabric and activates the hot-melt adhesive yarn, eliminating the need for separate energy inputs. This approach maintains bonding strength while reducing total energy consumption.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating process is made continuous and simultaneous rather than sequential. The thermal energy is applied once to achieve both heat-setting and adhesive activation in a single continuous action, eliminating the interruption and additional energy input that would occur with separate processes.

Inventive Principle:

Principle #20Continuity of useful action

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

The method enables efficient heat-setting and lamination of 3D knitted fabrics with reduced energy consumption and logistics costs, facilitating a more streamlined and cost-effective production process.

Implementation Method 1

activating the hot-melt adhesive yarn by way of the laminating apparatus for the heat-setting of the 3D knitted fabric

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the hot-melt adhesive yarn liquefies and consolidates the fibers in the knitted fabric upon cooling

Methodology Applied

Scientific EffectMelting and solidification: Melting

Implementation Method 3

laminating the heat-set 3D knitted fabric on the carrier device by way of the laminating apparatus

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS12330406B2Method for heat-setting and laminating a 3D knitted fabric, laminating apparatus, interior component and motor vehicle

Publication Date: 2025.06.17 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for heat-setting and laminating a 3D knitted fabric, which fabric has hot-melt adhesive yarn, on a carrier device for an interior component of a motor vehicle, includes the following steps: arranging the 3D knitted fabric on the carrier device in a laminating apparatus; activating the hot-melt adhesive yarn by way of the laminating apparatus for the heat-setting of the 3D knitted fabric; laminating the heat-set 3D knitted fabric on the carrier device by way of the laminating apparatus. A laminating apparatus for performing the heat-setting and laminating of the 3D knitted fabric on the carrier device is provided.