Air-permeable textile composite sheet for moisture management
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Solution Overview
Problem
Existing air-permeable textile composite webs fail to provide optimal moisture absorption and release in applications like upholstery and automotive seating, requiring active ventilation and lacking in manufacturing cost-effectiveness.
Innovation Solution
A composite material with a plastic upper side and a natural fiber or particle underside, laminated with foam or fleece, featuring a high proportion of cellulose fibers for reversible moisture absorption and release, enhancing climatic conditions and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional foam seat covers are used, then moisture absorption is limited, but the structure is simple and manufacturing is straightforward
Solution Approach 1:
The patent applies composite materials by combining synthetic foam layers with natural fiber layers (cotton, linen, wool, or blends) to create a multi-layer textile composite web. This composite structure integrates the moisture-wicking properties of natural fibers with the structural stability of synthetic foam, achieving superior moisture absorption and release capabilities while maintaining manufacturing feasibility through established lamination techniques.
Solution Approach 2:
The patent implements local quality by creating distinct layers with different functional properties: the synthetic foam layers provide structural support and baseline moisture management, while the natural fiber layers specifically targeted for enhanced moisture absorption and release. This localized functional differentiation allows each layer to optimize its specific role in the moisture management system.
2Reliability
If active ventilation is implemented, then moisture release is improved, but energy consumption increases and device complexity increases
Solution Approach 1:
The patent applies self-service by designing a passive moisture management system where the composite web structure itself performs moisture absorption and release without requiring external energy input or active ventilation mechanisms. The natural fiber layers automatically absorb moisture from the user, and the foam structure facilitates passive evaporation and release, making the system self-regulating and energy-independent.
Solution Approach 2:
The patent extracts the active ventilation system from the moisture management solution, replacing it with a passive material-based approach. By removing the need for mechanical ventilation components and their associated energy consumption, the invention achieves moisture release through the inherent properties of the composite web materials alone.
3Reliability
If natural fibers are used in high proportion, then moisture absorption is improved, but manufacturing cost may increase
Solution Approach 1:
The patent applies parameter changes by optimizing the proportion of natural fibers within a practical range (30-70% by weight) rather than using extreme values. This optimization balances moisture absorption performance with manufacturing cost considerations, finding the sweet spot where sufficient natural fiber content delivers the required climatic effect while maintaining cost-effectiveness for mass production in the automotive industry.
4Strength
If high basis weight is used, then durability is improved, but stretchability may be reduced
Solution Approach 1:
The patent uses composite materials to resolve the contradiction between durability and stretchability. The synthetic foam layers provide structural strength and durability, while the natural fiber layers contribute to flexibility and stretchability. This composite combination allows the overall web to achieve both high basis weight for durability and sufficient elongation properties for comfort and fit.
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 achieves excellent climate comfort, high durability, and cost-effective production by maintaining optimal moisture absorption and release without active ventilation, as evidenced by a climate quality number between 13 and 15, significantly improving upon conventional foam seat covers.
Implementation Method 1
an underside made of natural fibers or particles with a hydrophilic character and reversible moisture absorption and release
Implementation Method 2
the corresponding release of the absorbed moisture into the ambient air
Data Source
AI summary
A textile air-permeable composite material has upper surface made of plastic, lower surface made of hydrophilic particles or natural fibers, and foam material or nonwoven fabric which covers the lower surface.