Low-Temperature Binder Curing for Hybrid Automotive Seat Padding
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Solution Overview
Problem
Existing methods for manufacturing upholstery elements, such as those using flexible polyurethane foam or fiber composite materials, are complex and expensive, often requiring high-temperature vulcanization and drying processes that can damage insert materials and limit material choices.
Innovation Solution
The use of PES/PET fibers dried with a polyurethane or chloroprene-based binder that cures at temperatures below 120°C, allowing for the integration of various insert materials without vulcanization and intensive drying, enabling the production of a dimensionally stable and elastic upholstery element with reduced processing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature vulcanization and intensive drying processes are used to manufacture fiber composite upholstery elements, then the binder achieves sufficient bonding strength and dimensional stability, but the insert materials are damaged and the processing time increases
Solution Approach 1:
The patent changes the curing temperature parameter from high-temperature vulcanization (typically 120°C or higher) to low-temperature curing (below 120°C). This parameter change allows the binder to achieve sufficient bonding strength without exposing insert materials to damaging high temperatures, thereby resolving the contradiction between bonding strength and material protection
Solution Approach 2:
The patent uses a disposable absorbent material (such as cellulose wadding or paper) that is placed between the binder and insert materials during the curing process. This disposable material absorbs excess binder and protects the insert materials from direct contact with the binder and heat, then is removed after curing. This allows achieving strong bonding without damaging the insert materials
2Strength
If high-temperature vulcanization and intensive drying processes are used to manufacture fiber composite upholstery elements, then the binder achieves sufficient bonding strength and dimensional stability, but the processing time increases
Solution Approach 1:
The patent changes the curing temperature parameter to below 120°C and optimizes the curing time parameter to achieve sufficient bonding strength in a shorter time. This parameter optimization allows the binder to cure adequately without requiring lengthy high-temperature processing, thereby reducing the dwell time in the mold while maintaining bonding strength
Solution Approach 2:
The patent applies the binder to the insert materials or carrier structure before placing them in the mold, allowing the binder to begin its curing process immediately upon closure. This preliminary action reduces the total curing time required in the mold while ensuring sufficient bonding strength is achieved
3Strength
If traditional fiber composite manufacturing methods are used, then the upholstery element achieves sufficient structural integrity, but the ventilation performance is poor
Solution Approach 1:
The patent uses different types of fibers in different regions of the upholstery element. The carrier structure uses dense fibers for structural integrity, while the insert materials use open, breathable fibers for ventilation. This local differentiation of fiber properties allows the element to simultaneously achieve structural strength and breathability
Solution Approach 2:
The patent combines different materials (fibers, foam, textiles, natural materials) with complementary properties to create a composite upholstery element. The fiber matrix provides structural integrity while the porous structure and breathable insert materials provide ventilation, achieving both structural strength and breathability through material composition
4Adaptability or versatility
If diverse insert materials are used in the upholstery element, then the comfort and ventilation are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple different insert materials (fibers, foam, textiles, natural materials) into a single integrated upholstery element manufactured in one continuous process. The mold accommodates all these diverse materials simultaneously, and the binder cures them all together, eliminating the need for separate assembly operations and reducing manufacturing complexity despite material diversity
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
This approach allows for the use of diverse insert materials, including fibers, foams, and textiles, without damaging them, resulting in a cost-effective and comfortable upholstery element with improved ventilation and customizable comfort features.
Implementation Method 1
the binder-containing emulsion and the fibers are applied to the insert material in such a way that a random layer of fibers wetted with binder is formed on its surface, wherein the layer dries with drying air to form an elastic but dimensionally stable molded body
Data Source
Figure 1
Figure 2a~2d
Figure 3~4
AI summary
The invention relates to a hybrid cushion element, in particular a seat cushion element for use in a motor vehicle, to a method for producing a cushion element, and to a vehicle seat, wherein the cushion element has a non-woven fabric layer (4) and a fiber composite material (1), wherein an insert material (18, 182) is arranged between the non-woven fabric layer (4) and the fiber composite material (1). During the production in a mold, fibers for the fiber composite material (1) wetted with a binder are applied to the insert material (18, 182), wherein the insert material (18, 182) and the layer of fibers are then pressed to form a complex molded body, wherein the binder can be cured at a temperature less than 120°C.