Multi-layered fabric laminates and methods of making and using the same
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current mattress foundation designs using cardboard or densified fiber web insulating layers are prone to noise and require additional assembly steps, which can be costly and inefficient.
Innovation Solution
A multilayered fabric laminate comprising a first nonwoven fabric layer and a second needlepunched nonwoven fabric layer with fused fibers, providing enhanced bond strength and abrasion resistance to eliminate the need for additional insulating layers and reduce assembly operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cardboard or densified fiber web insulating layers are used, then abrasion resistance is improved, but device complexity increases due to additional assembly steps
Solution Approach 1:
The patent combines the filler cloth and insulating layer into a single integrated nonwoven fabric structure. The multilayered nonwoven fabric includes a first layer providing abrasion resistance and a second layer providing insulation, eliminating the need for separate cardboard or densified fiber web insulating layers. This merger reduces assembly complexity while maintaining both abrasion resistance and insulation properties.
2Duration of action of stationary object
If separate insulating layers are used, then durability is improved, but manufacturing time increases due to additional assembly operations
Solution Approach 1:
The patent integrates the insulating function directly into the filler cloth by creating a multilayered nonwoven fabric structure. This eliminates the need for separate assembly operations to install insulating layers, thereby reducing manufacturing time while maintaining the durability benefits of having both abrasion-resistant and insulating properties in a single integrated component.
3Reliability
If multiple separate layers are used, then functional performance is improved, but ease of manufacture decreases
Solution Approach 1:
The patent creates a composite multilayered nonwoven fabric where different layers serve different functions: the first layer provides abrasion resistance and the second layer provides insulation. These layers are bonded together to form a single integrated material that delivers both functions simultaneously, improving ease of manufacture compared to assembling separate components while maintaining high functional performance.
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 multilayered fabric laminate offers increased durability and abrasion resistance, reducing noise and assembly costs, while providing opacity and abrasion resistance without the need for separate insulating layers, thus enhancing the manufacturing process and product performance.
Implementation Method 1
at least one surface of the needlepunched nonwoven fabric comprises fused fibers
Implementation Method 2
Insulating layers also provide opacity and cushioning that help obscure the steel wire grid or wooden slats in the foundation frame
Data Source
AI summary
Multi-layered fabric laminates, such as, for example, those used as filler cloths and/or in manufacturing mattress foundations, are described along with methods of making and/using the same.