Elastic Textile Composite Structure for Vehicle Interiors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite structures lack a highly elastic textile layer with high elongation at low elongation force, and they do not achieve the desired balance of elasticity and strength without using a foam layer.
Innovation Solution
A composite structure comprising an elastic textile layer and a polymeric cover layer, where the textile layer shows at least 20% elongation at 50 N and 50% elongation at 100 N in both directions, with a burst load of 250 to 600 N, and the cover layer is directly bonded to the textile layer, either thermally or using an adhesive, to achieve enhanced elasticity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a foam layer is used to provide elasticity and softness, then the composite structure achieves desired elasticity and softness, but the structure becomes more complex and requires additional materials
Solution Approach 1:
The patent removes the foam layer from the composite structure, extracting the unnecessary component while retaining the essential functionality. The textile layer alone provides the required elasticity and softness through its inherent material properties and construction, eliminating the need for the separate foam layer and simplifying the overall structure.
Solution Approach 2:
The patent uses a composite textile layer combining different fiber types (elastic fibers, reinforcing fibers, and softening fibers) to achieve the desired elasticity and softness. This composite material approach allows the single textile layer to perform multiple functions that previously required separate foam and textile layers.
2Ease of operation
If the textile layer is made highly elastic with high elongation, then the composite structure shows improved elasticity, but the strength and burst load may be compromised
Solution Approach 1:
The patent applies different fiber types in specific proportions within the textile layer to create local functional zones. Elastic fibers (at least 10 mass%) provide elongation capability, while reinforcing fibers provide strength and burst load resistance. This local quality distribution allows the textile layer to simultaneously achieve high elasticity and maintain sufficient strength.
Solution Approach 2:
The textile layer is constructed as a composite material system combining elastic fibers, reinforcing fibers, and softening fibers. This composite structure enables the layer to exhibit both high elongation (at least 100% at 50 N force) and adequate burst load resistance (at least 250 N) by leveraging the complementary properties of different fiber types.
3Ease of manufacture
If the cover layer is directly bonded to the textile layer without foam, then the production is simplified, but the bonding strength and structural integrity must be maintained
Solution Approach 1:
The patent removes the foam layer that previously served as an intermediate bonding layer, simplifying the production process. The cover layer is now directly bonded to the textile layer, reducing the number of assembly steps and materials required while maintaining structural integrity through optimized bonding parameters.
Solution Approach 2:
The patent employs thermal bonding or thermo-mechanical bonding with optimized temperature, pressure, and time parameters to achieve strong bonding between the cover layer and textile layer. By carefully controlling these parameters, the direct bonding process maintains bonding strength equivalent to or exceeding traditional foam-based bonding, while simplifying production.
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 composite structure provides a balance of elasticity, strength, and softness, facilitating easy processing and handling, such as cutting and sewing, without the need for a foam layer, while maintaining desired properties like burst load and elongation.
Implementation Method 1
the cover layer and the textile layer are thermally bonded to each other
Implementation Method 2
the textile layer is elastic and shows an elongation, preferably both in a first direction and in a second direction perpendicular to the first direction, of at least 100 % at an elongation force of 50 N
Data Source
AI summary
A composite structure comprising a textile layer and a cover layer, wherein the composite structure is elastic and shows an elongation of at least 20 % at an elongation force of 50 N; a method of preparing the composite structure; and the use of the composite structure as a surface material in the interior of a vehicle.