Vehicle Floor Carpet Structure to Suppress Bagginess
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Solution Overview
Problem
Existing vehicle floor carpets face issues of increased manufacturing costs and weight due to repeated stacking and compressing processes to eliminate bagginess, leading to unnecessary material usage and weight gain.
Innovation Solution
A vehicle floor carpet design incorporating a non-woven insulator with load-bearing walls and compressive portions to support the space between the floor panel and carpet body, using a non-woven sheet and carpet body to absorb irregularities and prevent sinking, while maintaining a flat surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated stacking and compressing of webs is performed to eliminate bagginess, then bagginess is suppressed, but manufacturing cost and weight increase
Solution Approach 1:
The invention changes the physical state of the insulator by compressing it to form load-bearing walls with specific density and rigidity parameters. This single compression process creates sufficient structural support to eliminate bagginess without requiring multiple stacking and compressing operations, thereby reducing weight while maintaining reliability.
Solution Approach 2:
The invention uses a composite structure combining the insulator material with the carpet body and floor panel, where the compressed insulator forms load-bearing walls that integrate with the carpet structure. This composite approach provides the necessary mechanical support to prevent bagginess without adding excessive weight through multiple separate layers.
2Reliability
If repeated stacking and compressing of webs is performed to eliminate bagginess, then bagginess is suppressed, but manufacturing cost increases
Solution Approach 1:
The invention modifies the insulator's physical parameters through a single compression process to achieve the desired load-bearing capacity. This eliminates the need for repeated stacking and compressing operations, thereby reducing manufacturing complexity and cost while ensuring bagginess suppression.
Solution Approach 2:
The invention extracts and eliminates the unnecessary repeated stacking and compressing steps from the manufacturing process. By forming load-bearing walls through a single compression operation, the process removes redundant operations that increase manufacturing cost, while still achieving the required suppression of bagginess.
3Reliability
If more web material is used to form projections, then bagginess is suppressed, but material cost and weight increase
Solution Approach 1:
The invention changes the density and compression parameters of the insulator material to create load-bearing walls that provide structural support. This approach uses the material more efficiently through compression rather than adding more material, thereby suppressing bagginess while reducing the total quantity of web material required.
Solution Approach 2:
The invention applies local compression to specific regions of the insulator to form load-bearing walls where structural support is needed. This localized approach to material modification ensures that material is used only where necessary to prevent bagginess, rather than uniformly increasing material quantity throughout the entire carpet structure.
Data Source
AI summary
Provided is a vehicle floor carpet which can suppress the occurrence of bagginess without causing an increase in manufacturing cost and an increase in weight. The vehicle floor carpet includes an insulator including a non-woven sheet, a carpet body disposed on and covers an upper surface of the insulator, and a load-bearing wall which is a compressed portion of the insulator and which extends between a floor panel and the carpet body and supports the floor panel and the carpet body and preserves a space between the floor panel and the carpet body.