Laser-Ablated Composite Material for Breathable Seat Coverings
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Solution Overview
Problem
Current methods for creating air and water vapor permeability in composite materials, such as those used in motor vehicle seat coverings, are inefficient, as punching damages the material and needling results in non-permanent openings with rough surfaces and limited design variability.
Innovation Solution
The use of laser ablation to create cavities in composite materials, allowing for precise control over size and depth of openings, which can penetrate the entire thickness of the material and vary in shape and arrangement, enhancing permeability and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punching is used to create cavities, then passage openings are formed, but the supportive material is damaged and the process is complicated
Solution Approach 1:
The patent replaces the mechanical punching system with a laser-based system. The laser beam (electromagnetic energy) ablates the material to create cavities without mechanical contact, eliminating damage to the supportive material while maintaining precise cavity formation.
Solution Approach 2:
The patent changes the physical state and properties of the material through laser heating. The laser energy transforms the material locally, creating cavities through thermal ablation rather than mechanical force, thereby preserving the surrounding material integrity.
2Strength
If needling is used to create passage openings, then the supportive material remains undamaged, but the passage openings have a tendency to reclose and the surface becomes rough
Solution Approach 1:
The patent replaces the mechanical needling system with laser ablation. The laser creates permanent cavities through material removal rather than mechanical displacement, preventing reclosure while maintaining surface smoothness without crust formation.
Solution Approach 2:
The laser induces phase transitions in the material (melting, vaporization) to create permanent cavities. This thermal processing ensures the cavities remain open and stable without relying on mechanical deformation that can reclose.
3Reliability
If hot needles are used for permanent perforation, then passage openings are created, but crusts form at the edges and the surface becomes rough
Solution Approach 1:
The patent replaces hot needling with laser ablation. The laser beam delivers controlled energy that vaporizes material cleanly without the mechanical disruption and crust formation associated with hot needle perforation, maintaining surface smoothness.
Solution Approach 2:
The laser selectively removes (ablates) only the material needed for cavity formation, taking out precisely the required amount without excessive heating or crust formation on surrounding surfaces, thereby preserving surface quality.
4Ease of manufacture
If conventional punching or needling is used, then passage openings are formed, but the arrangement and shape are limited to stereotypical patterns
Solution Approach 1:
The laser system allows dynamic control of cavity parameters during processing. The beam can be programmed to create varying shapes, sizes, depths, and patterns in real-time, enabling high design versatility while maintaining manufacturing efficiency through automated control.
Solution Approach 2:
The laser system enables continuous variation of cavity parameters (shape, size, depth, distribution) by adjusting beam parameters and processing paths. This provides unlimited design flexibility compared to fixed mechanical tools, while maintaining ease of manufacture through programmable control.
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 method improves the water vapor transmission of composite materials while maintaining strength and surface smoothness, allowing for customizable designs that meet industry standards without impairing material durability.
Implementation Method 1
the cavities and passage openings are produced by a laser, or that the material required for the formation of the cavities is removed by laser ablation
Data Source
AI summary
The invention relates to a process for the production of a composite material, by bonding a supportive layer to an upper layer (1) made of polyurethane or flexible PVC, where the supportive layer (2) is a textile material, e.g. woven fabric, knitted fabric or nonwoven microfiber fabric, or a leather, in particular a split cowhide leather, and the upper layer (1) comprises, bonded to one another, a number of polyurethane layers or a number of flexible PVC layers (1′, 1″). The invention provides thatin the composite of upper layer (1) and supportive layer (2), proceeding from the surface of the upper layer (1), channel-shaped cavities (6) for the passage of water vapor and/or air are formed via ablation of material by a laser in a manner such thatat least some of the cavities (6) penetrate the entire thickness of the material of the upper layer (1) and/or terminate before entry into that region of the volume of the supportive layer (2) that is free from the material of the upper layer (1).