Multi-layer comfortable air fiber structure, preparation method therefor, and seat cushion, backrest and seat prepared therefrom
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Solution Overview
Problem
Existing seat cushions and backrests formed from single-layer air fiber sheets exhibit uneven density and hardness, leading to inconsistent comfort and material waste due to excessive compression during the forming process.
Innovation Solution
A multi-layer air fiber structure comprising a comfortable upper layer and a supportive lower layer, formed by hot-pressing air fiber sheets with different spinning directions, mechanically connected to ensure consistent density and hardness, reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single-layer air fiber sheets are used for seat cushion and backrest, then the structure is simple and manufacturing is easy, but the density and hardness are uneven leading to poor comfort
Solution Approach 1:
The single-layer air fiber sheet is divided into multiple layers with different spinning directions. The first layer has fibers spinning in a first direction while the second layer has fibers spinning in a second direction different from the first direction, creating distinct functional zones that address both structural simplicity and comfort requirements
Solution Approach 2:
Different regions of the seat cushion and backrest are created with different fiber orientations. The first layer provides uniform support while the second layer with different spinning direction provides localized comfort zones, ensuring each part performs its specific function optimally
2Quantity of substance
If excessive compression is applied during hot-pressing of single-layer air fiber sheets, then the density increases, but material waste increases and hardness becomes uneven
Solution Approach 1:
The compression process is segmented into two stages corresponding to two layers. The first layer is hot-pressed to achieve initial density, then the second layer is hot-pressed with different compression parameters. This segmented approach optimizes material utilization and reduces waste while achieving target density
Solution Approach 2:
Different hot-pressing parameters are applied to different layers. The first layer uses specific temperature and pressure parameters, while the second layer uses modified parameters to achieve optimal density without excessive compression, thereby reducing material waste
3Ease of manufacture
If single-layer air fiber sheets are hot-pressed, then the manufacturing process is simple, but the hardness is uneven throughout the seat cushion
Solution Approach 1:
The manufacturing process is segmented into sequential hot-pressing of first and second layers. Each layer is processed with controlled parameters, and the layered structure ensures hardness uniformity throughout the final product while maintaining manufacturing simplicity through standardized multi-layer assembly
Solution Approach 2:
Two layers of air fiber sheets with different fiber spinning directions are combined into a composite structure. This composite material approach ensures uniform hardness distribution while maintaining ease of manufacture through standardized layering and hot-pressing processes
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 multi-layer structure achieves even density and hardness, enhancing comfort while minimizing material usage and waste, with a weight reduction of over 25% compared to single-layer structures.
Implementation Method 1
the comfortable upper layer and the supportive lower layer are respectively formed by hot-pressing single-layer air fiber sheets
Implementation Method 2
a front seat cushion is disclosed, which comprises independently provided transverse pieces, the pieces being then melt-spliced
Data Source
AI summary
The multi-layer comfortable air fiber structure disclosed in the present invention comprises a comfortable upper layer and a supportive lower layer, wherein the comfortable upper layer and the supportive lower layer are respectively prepared by hot pressing single-layer air fiber sheets formed from air fibers with different spinning directions, and a bottom surface of the comfortable upper layer is mechanically connected with an upper surface of the supportive lower layer. The present invention also discloses a preparation method for the multi-layer comfortable air fiber structure. The backrest or the backrest disclosed in the present invention is prepared from the above-mentioned multi-layer comfortable air fiber structure. The seat disclosed in the present invention is formed by the above seat cushion and backrest. The present invention meets the demand for comfort by adjusting the density and hardness of the comfortable upper layer and the supportive lower layer, and meanwhile achieves the purpose of saving materials.