Extensible Paper Laminates for Automotive Seat Stiffeners
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Solution Overview
Problem
Conventional multi-layered paper structures are either too rigid and stiff, making them prone to fracture during processes like the inverter machine process, or too flexible, lacking the necessary stiffness for applications like automotive seat stiffeners.
Innovation Solution
A multi-layered laminated paper structure comprising extensible and non-extensible kraft paper layers, with a basis weight of 25-400 pounds per 3000 sq. ft., bonded with an adhesive to achieve a balance of rigidity, stiffness, and flexibility, allowing the paper to bend without breaking and maintain integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solid laminated paperboard is used to replace plastic in automotive seat applications, then cost is reduced and recyclability is improved, but the board fractures and fails during the inverter machine process due to excessive stiffness
Solution Approach 1:
The patent uses multi-layered laminated paperboard constructed from different types of paper (e.g., kraft paper, sulfate paper, newsprint) bonded together with adhesives. This composite structure combines layers with different mechanical properties to achieve both flexibility for the inverter process and sufficient stiffness for structural support, while maintaining cost-effectiveness and recyclability compared to solid plastic alternatives.
Solution Approach 2:
The patent modifies the physical and mechanical parameters of the paperboard by controlling the basis weight, thickness, and adhesive content of each layer. By adjusting these parameters, the paperboard achieves optimal balance between flexibility (to prevent fracture during inversion) and stiffness (to provide structural support), resolving the contradiction between manufacturability and reliability.
2Strength
If traditional adhesives are used to laminate paper plies, then bond strength is achieved, but the finished laminate becomes excessively stiff and rigid
Solution Approach 1:
The patent selects and formulates adhesives with specific properties including lower viscosity, controlled solid content, and appropriate flexibility. By changing the adhesive parameters (such as using polymer emulsions instead of rigid adhesives), the laminate maintains strong bonding between layers while preserving the flexibility needed to prevent fracture during the inverter machine process.
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 structure provides a flexible yet rigid solution that can withstand the inverter machine process and other applications, offering a cost-effective, recyclable alternative to plastic and wood, with adjustable rigidity and stiffness characteristics.
Implementation Method 1
a layer of adhesive which bonds each of the at least two layers of extensible or non-extensible kraft paper together
Data Source
AI summary
A multi-layered laminated paper structure that has at least two layers of an extensible kraft paper is provided. The extensible kraft paper has a basis weight of 25-400 pounds per 3000 sq. ft. The multi-layered laminated paper structure also has one or more layers of a non-extensible kraft paper and a layer of adhesive which bonds each of the at least two layers of extensible or non-extensible kraft paper together to form a flexible solid multi-layered laminated paper structure.