Method for manufacturing a seat padding and seat padding as such
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Solution Overview
Problem
Existing seat padding materials, typically made of urethane polymer foam, suffer from moisture retention in humid conditions and lack effective attachment methods that do not risk tearing the material.
Innovation Solution
A method involving the manufacturing of seat padding with a 3D tangle of continuous thermoplastic fibers arranged irregularly, where local areas are densified and stiffened through hot pressing to create fixing zones, using thermoforming to form elastic lips, hooks, or through slots for secure attachment without tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If urethane polymer foam is used for seat padding, then the padding provides softness and comfort, but it retains moisture in humid conditions
Solution Approach 1:
The patent uses a 3D tangle of continuous thermoplastic fibers with inherent porosity between the fibers. This porous structure allows air circulation and prevents moisture retention while maintaining the softness and comfort required for seat padding.
Solution Approach 2:
The patent creates a composite structure by combining thermoplastic fibers with a 3D tangle configuration. This composite material provides both the comfort needed for seating and the moisture resistance that pure foam materials cannot achieve.
2Ease of operation
If attachment inserts are trapped in foam by overmolding, then the cover can be fixed to the padding, but the foam structure may be damaged or the attachment may not be secure
Solution Approach 1:
The patent applies local quality by creating densified zones at specific locations within the 3D fiber tangle. These localized densified areas provide secure attachment points for covers while the rest of the padding maintains its soft, breathable structure.
Solution Approach 2:
The patent changes the density parameter locally within the padding structure. By hot pressing specific areas, the fiber density increases in those zones, creating stiffened regions that can securely hold attachment inserts without damaging the overall padding structure.
3Adaptability or versatility
If the 3D fiber structure is compressed to create fixing zones, then attachment capability is improved, but the overall padding thickness and softness may be reduced
Solution Approach 1:
The patent applies local quality by creating densified zones at specific locations within the 3D fiber tangle. These localized densified areas provide secure attachment points for covers while the rest of the padding maintains its soft, breathable structure.
Solution Approach 2:
The patent uses partial action by compressing only specific local areas of the padding rather than the entire structure. This partial compression creates fixing zones while preserving the overall thickness and softness of the padding in non-compressed areas.
4Reliability
If hot pressing is applied to densify local areas, then attachment security is improved, but energy consumption and processing time increase
Solution Approach 1:
The patent uses partial action by compressing only specific local areas of the padding rather than the entire structure. This partial compression creates fixing zones while preserving the overall thickness and softness of the padding in non-compressed areas.
Solution Approach 2:
The patent segments the padding structure into different functional zones: soft breathable areas for comfort and densified zones for attachment. This segmentation allows hot pressing to be applied only where needed, reducing overall energy consumption compared to treating the entire padding structure.
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 method provides a padding with enhanced moisture resistance and secure attachment capabilities, ensuring durability and comfort by preventing loop tearing while maintaining breathability.
Implementation Method 1
extrusion of a thermoplastic polymer in an extrusion die comprising extrusion nozzles distributed along a lengthwise direction and along a widthwise direction of the extrusion die, generating a curtain of continuous molten fibers, falling by gravity
Implementation Method 2
solidification of the 3D entanglement of fibers by immersion in a cooling liquid
Implementation Method 3
Hot pressing the 3D tangle of fibers into one or more local areas of the 3D tangle so as to obtain one or more local areas of the padding that are densified and stiffened
Implementation Method 4
the hot pressing in one or more local areas of the padding causes compression by a partial reduction in the thickness (EP) of the 3D entanglement in the local area, of at least 30% depending on the thickness
Implementation Method 5
the pressing is a thermoforming step during which a first mold part and a second mold part transform the fibers of the 3D entanglement of the local area into two elastic lips
Data Source
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AI summary
This disclosure relates to a method for manufacturing a seat cushion (3) comprising: - /A/ Providing a cushion comprising a 3D entanglement of continuous thermoplastic fibers arranged irregularly or randomly forming loops welded together, - /B/ Hot pressing the 3D fiber entanglement in one or more local areas of the 3D entanglement so as to obtain one or more densified and stiffened local areas (LAs) of the cushion, the local area(s) being configured to serve as an attachment area. This disclosure further relates to a cushion obtained according to the manufacturing method, and a seat comprising such cushioning and a cover (CL) attached in the densified and stiffened local area(s) (LAs).