3D Mesh Seat Upholstery Laminate for Ventilation and Seam Stability
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Solution Overview
Problem
Current seat and backrest trim complexes in motor vehicles suffer from suboptimal comfort due to humidity issues and limited ventilation, leading to aesthetic defects and discomfort for passengers.
Innovation Solution
A complex comprising an air-permeable external covering, a three-dimensional mesh internal supporting sheet, and a crosslinked open-cell foam layer, secured via seams that prevent seam lines from rising, ensuring ventilation and enhanced comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If perforations are made in the external covering and internal carrier sheet to provide ventilation, then moisture evacuation is improved, but aesthetic appearance deteriorates due to seam line rising at perforated areas
Solution Approach 1:
The invention extracts the stitching function from the foam layer by using a knit carrier sheet that inherently holds the stitching in place. The stitching lines are taken out of direct contact with the foam layer, eliminating the cause of seam line rising while maintaining the ventilation function through perforations in the carrier sheet.
Solution Approach 2:
The knit carrier sheet acts as an intermediary layer between the foam layer and the stitching lines. It prevents direct contact between the stitching and foam, thereby preventing seam line rising while still allowing ventilation through its perforated structure. The carrier sheet mediates between the structural requirements and the aesthetic requirements.
2Stability of the object's composition
If a traditional carrier sheet is used with stitching lines contacting the foam layer, then structural stability is maintained, but seam lines rise at perforated areas causing aesthetic defects
Solution Approach 1:
The invention uses a knit carrier sheet with a porous, mesh-like structure that provides both geometric stability and flexibility. The knit structure inherently stabilizes the stitching lines preventing them from rising, while the porosity allows ventilation through the material without compromising structural integrity.
Solution Approach 2:
The invention changes the physical parameters of the carrier sheet by using a knit structure with specific elasticity and permeability characteristics. This knit structure has different mechanical properties compared to traditional sheets, allowing it to stabilize stitching while accommodating ventilation requirements.
3Manufacturing precision
If the internal carrier sheet material is changed to prevent seam line rising, then aesthetic appearance is improved, but ventilation function may be compromised
Solution Approach 1:
The knit carrier sheet is specifically designed as a porous material with a mesh structure that provides both seam line stability and ventilation functionality. The porosity of the knit structure allows air and moisture to pass through while the knit pattern itself prevents seam line rising.
Solution Approach 2:
The invention uses a composite structure combining the knit carrier sheet with the foam layer and external covering. The knit sheet serves multiple functions simultaneously: stabilizing stitching, allowing ventilation, and preventing seam line rising, creating a multi-functional composite material system.
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 solution provides improved aesthetic rendering, increased comfort, and effective ventilation, preventing humidity buildup while maintaining geometric stability and mechanical performance.
Implementation Method 1
In order to ensure a certain level of ventilation to evacuate this moisture
Implementation Method 2
a layer of open-cell foam
Data Source
Figure 1~4
AI summary
The present invention relates to a soft trim cover laminate (100) for a motor vehicle seat base or seat backrest upholstery, comprising: - an outer air-permeable covering (101) made of textile, leather or synthetic material, - a supporting inner sheet (103) also air-permeable and made of a textile material, and - a layer of open-cell foam (102) positioned between said outer covering (101) and said supporting inner sheet (103), said outer covering (101), said layer of foam (102) and said supporting inner sheet (103) being secured to one another via a plurality of seam lines (104); characterised in that said supporting inner sheet (103) is formed by a three-dimensional mesh textile. The invention also relates to a soft trim cover for a seat base or backrest comprising at least one such laminate.