Compensation Layer Compression for Vehicle Interior Cushioning
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Solution Overview
Problem
Conventional non-woven knitted pile fiber fabrics have limited compression resistance and resistance to pressure marks due to the length of pile fiber bundles, which affects their mechanical properties and haptic quality in applications like motor vehicle interiors.
Innovation Solution
A method involving the translatory displacement and fixation of fiber stitch layers in non-woven knitted pile fiber fabrics to deform pile fiber bundles, reducing the distance between layers, increasing internal stress, and enhancing compression resistance, strength, and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the length of pile fiber bundles is increased to improve cushioning and comfort, then the compression resistance of the compensation layer is reduced
Solution Approach 1:
The patent applies preliminary action by pre-compressing the pile fiber bundles during the production process using calendar rollers. This pre-compression reduces the distance between the upper and lower fiber stitch layers, creating internal stress in the pile fibers before the product is put into use. As a result, the compensation layer achieves both the cushioning effect of longer pile fibers and improved compression resistance, as the pre-compressed structure resists further compression during normal use.
2Reliability
If the length of pile fiber bundles is increased to improve resilience, then the resistance to pressure marks is reduced
Solution Approach 1:
The patent applies preliminary action by pre-compressing the pile fiber bundles during production using calendar rollers. This pre-compression creates internal stress in the pile fibers and reduces the distance between fiber stitch layers before the product is put into use. The pre-compressed structure provides both improved resilience for recovering from deformations and increased resistance to pressure marks, as the internally stressed fibers resist permanent deformation during normal use.
3Strength
If the distance between fiber stitch layers is reduced to improve compression resistance, then the voluminous structure is compromised
Solution Approach 1:
The patent applies preliminary action by pre-compressing the pile fiber bundles during production to reduce the distance between fiber stitch layers. This creates internal stress that improves compression resistance. The key is that this pre-compression is applied selectively during manufacturing, allowing the product to achieve both reduced layer distance for strength and maintained voluminous appearance for aesthetic purposes, as the pre-compressed structure resists further compression.
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 significantly improves compression resistance, strength, and resistance to pressure marks, while maintaining a uniform and even surface appearance, by compacting and pre-tensioning the pile fibers, resulting in a more resilient and aesthetically pleasing compensation layer.
Implementation Method 1
causing an essentially translatory displacement of the fiber stitch layers relative to one another so that the pile fiber bundles are deformed and the distance between the first and the second fiber stitch layer is reduced
Implementation Method 2
fixing the pile fiber bundles in their deformed condition... The subsequent deformation of the pile fiber bundles permanently maintains the internal stress and therefore leads to an improvement of the compression resistance, the resistance to pressure marks, and the sustained resilience
Data Source
AI summary
A method for processing a compensation layer, used in a vehicle interior, to increase a pressure resistance of the compensation layer. The method includes providing an unprocessed compensation layer. The compensation layer includes a first layer formed of fiber stitches, a second layer formed of fiber stitches, and a plurality of pile fiber bundles, each formed of pile fibers, connecting the first and second layers. The method further includes displacing the first and second layers substantially translatorily towards one another to thereby deform the pile fiber bundles into a deformed state, such that a distance between the first and second layers is reduced. The method also includes fixing the pile fiber bundles in the deformed state, such that the pressure resistance of the compensation layer in the deformed state is greater than the pressure resistance of the unprocessed compensation layer.